Patent Publication Number: US-9849931-B2

Title: Method for forming bicycle frame assembly with integral fastener passage

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application is a Divisional of U.S. application Ser. No. 13/735,022, filed Jan. 6, 2013, titled BICYCLE FRAME ASSEMBLY WITH INTEGRAL FASTENER PASSAGE, now U.S. Pat. No. 9,120,525, which is a Continuation of U.S. application Ser. No. 13/178,866, titled BICYCLE FRAME ASSEMBLY WITH INTEGRAL FASTENER PASSAGE, filed Jul. 8, 2011, now abandoned, both of which are incorporated herein by reference in their entireties. 
    
    
     BACKGROUND OF THE INVENTION 
     The present invention relates generally to bicycles and, more particularly, to bicycle frame structures having an integrally formed passage constructed to sleekly and conveniently accommodate a fastener useable for securing supplemental structures, such as brake or shift control cables, or other bicycle accessories or mounting bosses to the underlying frame of the bicycle assembly. 
     During cycling, the cyclist interacts with a number of control systems, such as brake and shift systems that effect operation of the bicycle. As is commonly understood, both such systems commonly include an operator, such as brake or shift lever, that is commonly situated proximate the grip areas of a handlebar. Rider interaction with the respective lever facilitates movement of structures of the bicycle, such as a brake device or chain derailleur. Commonly, an elongate member, such as a cable or fluid connector, extends between the operator and the system whose operation is controlled by the lever. 
     With respect to the braking systems, rider manipulation of a respective brake lever causes manipulation of the elongate member which in turn causes actuation of a brake system. Understandably, bicycles can be provided with only front brake systems, only rear brake systems, or both front and rear brake systems. Such brake systems are commonly provided as rim brake systems whereby brake pads interact with a rim of a corresponding wheel or as disk brake systems wherein brake pads interact with a brake disk that is positioned nearer the hub of a respective wheel than the rim of the corresponding wheel. Regardless of the specific configuration of the brake system or the number of braking systems a bicycle is provided with, the elongate member communicates the rider&#39;s instructions from the brake lever to a corresponding brake system to slow the bicycle. 
     Like brake systems, many bicycles are provided with multi-geared drive train systems. Such systems commonly include a cassette or gear set that is attached to a rear wheel of the bicycle and a crankset that is attached to the pedals of the bicycle. In many high performance bicycles, each of the crankset and the gear set include multiple gears of varied diameters. A flexible drive member, such as a chain or a belt, operationally engages each of the gear set and the crankset and communicates the rider pedal force from the crankset to the wheel gear set. A derailleur is positioned proximate each of the multi-geared crankset and gear set to effectuate shifting of the belt or chain between the various gears of the respective set. As is commonly understood, riders frequently shift the chain between the various gears to maintain a desired cadence associated with a given ride environment. Said in another way, riders can shift the belt or chain from operative interaction with the various gears of the cassette or gear set and/or the crankset to maintain a desired torque associated with desired operation of the pedals. 
     Like brake systems, gear train shift controls commonly include a handle or shift lever that is also positioned proximate the handlebars, the respective derailleur, and an elongate member or shift cable that extends between the respective shift lever and the corresponding derailleur. Operation of a respective shift lever laterally translates a corresponding derailleur which in turn biases the flexible drive member, be it a chain or a belt, into engagement with an adjacent gear associated with the respective gear set or crankset. The elongate operator extends between the shift lever and a respective front or rear derailleur and communicates the rider&#39;s shift instructions to the respective gear set or crankset of gears. 
     Commonly, a single lever assembly can be provided which has multiple operational directions so that both braking and shifting can be effectuated with a single lever assembly. Regardless of the specific construction of the given lever system and the operation of the corresponding derailleur or brake system, an elongate member, commonly in the form of a sheathed cable and less frequently in the form of a hydraulic control cable or an electrical cable, extends between the respective lever assembly and the corresponding operational system. These elongate members must be secured to the underlying bicycle in a manner such that operation of a given lever assembly yields repeatable operation of the underlying brake and/or derailleur systems. Commonly, the lever end and a system end of the elongate member must be secured to the underlying bicycle so that a cable is freely translatable without interference from either the sheath of the cable or the mounting assembly. Likewise, the elongate members must also be periodically secured to the underlying bicycle frame or adjacent structure to prevent undesired snagging and/or movement of the underlying cable. 
     Many bicycle frames having external cable operating systems include integral cable mounts that are formed or secured to the bicycle frame at locations near the terminal ends of the respective operational ends of the cable and intermediate locations along extended lengths of the control cable. Such systems commonly require elongate members that are specifically or uniquely configured for interaction with a given bicycle configuration. Such a requirement unnecessarily increases the expense and expertise associated with both installing and replacing the elongate member associated with such control systems. Such systems are also susceptible to the drawbacks associated with a gap or space between the elongate member and the underlying bicycle frame as the mounting arrangements commonly create such a gap at least the distal sheathed ends of the elongate member as well as at discrete locations along the longitudinal length of the elongate member. Such spacing increases the footprint of the cross section associated with the elongated frame member and its associated signal conductors and can result in unintended interaction with the elongate control signal conductor. 
     Others, having recognized one or more of the shortcomings associated with such external mounting of the elongate control members, have turned to mounting arrangements wherein the elongate control members pass mostly, or at least partly, through the interior passages defined by the frame assembly of the bicycle. Although such systems provide substantial protection to the integrity of the elongate control member, such systems also present a number of drawbacks related to the construction of the underlying bicycle. Although the internal passages are generally free of obstructing structures, forming the openings and corresponding grommets associated with maintaining a sealed bicycle frame tends to complicate the overall construction and/or assembly of the underlying bicycle. Particularly problematic for such configurations are the pivotable or rotatable joints of the bicycle assembly, such as the steerer assembly, as well as the more congested areas of the bicycle structure, such as the bottom bracket assembly. Furthermore, some internal routing systems require disassembly of ancillary systems, such as the steerer assembly, the fork assembly, or the crankset assembly if service of the elongate control member is required. The various supplemental parts, tortuous routing, and commonly required sequential manipulation of ancillary systems can unduly complicate the manufacture, assembly, and serviceability of such internal cable routing methodologies. 
     Regardless of the interior or exterior routing of the elongate control members, formation of the mount supports associated with both such systems must be considered during the design and construction of the underlying bicycle frame and/or rigid frame members such as the top tube, the head tube, the down tube, the seat tube, the chain stays, the seat stays, and the fork legs. Supplemental manufacturing processes such as the welding or bonding of mount supports to the rigid members or the formation of supplemental openings or passages alters the structural performance of the respective frame member. Commonly, reinforcement is provided at the location of such mounts and/or the walls of the respective structural member are thicker than the nominal thickness of the elongated frame members. Such considerations complicate both the design and the construction of the rigid frame members of the bicycle assembly. 
     The various considerations discussed above with respect to the secure and compact association of the elongate control members relative to the bicycle frame members are equally applicable to the association of supplemental bicycle systems. Such systems can include bicycle performance monitoring systems, mounting of supplemental bicycle accessories, such as water bottles or water bottle mounts and cages, as well as other ancillary bicycling accessories. However, such systems are commonly secured to the bicycle frame in manners extraneous to the frame members and/or simply secured to the frame members with various adjustable and/or preformed clamping and/or mounting arrangements. Such methodologies can detrimentally impact the aerodynamic performance of the underlying bicycle and, in extreme cases, can mar or otherwise damage the finish of the frame member associated with such mounting arrangements. 
     Accordingly, it would be desirable to have a system and method of providing a bicycle frame or structure frame member of the bicycle that includes an integral mount for securing such components to the bicycle and which do so in a manner that does not appreciably complicate the design and/or manufacture of the frame member. It is further desirable to provide such a mount that is minimally or elastically pleasing regardless of interaction with such systems therewith. It is also further desired to provide a mounting arrangement that can be quickly and conveniently interacted with by users and/or other service personnel. The present invention discloses an assembly and method of forming such a mount. 
     BRIEF DESCRIPTION OF THE INVENTION 
     The present invention provides a bicycle frame assembly having at least one mount support that overcomes one or more of the above mentioned drawbacks. The bicycle frame assembly has a number of elongate tubes that are connected to define a shape of the bicycle frame. The assembly includes a passage that is defined by the elongate member, a partition, and a bridge. The partition isolates the passage from an interior volume of the elongate tube of the frame member. The bridge extends in a direction normal to an elongate direction of the passage and defines an inlet and an outlet of the passage. The inlet, outlet, and bridge are generally flush with an exterior surface of the elongate tube and provide a passage that cooperates with a flexible connector, such as a cable tie, for securing supplemental structures, such as brake and shift elongate control members and/or other bicycling accessories, to the elongate tube of the bicycle frame assembly. 
     One aspect of the invention useable with one or more of the features of the above aspects discloses a bicycle assembly that includes a plurality of elongate members that are connected and form a top tube, a head tube, a down tube, a seat tube, at least one chain stay, at least one seat stay, and at least one fork leg. At least one of the plurality of elongate members includes a hollow tube shape that is defined by a wall having an exterior surface and an interior surface that faces an interior cavity bounded by the wall. The at least one elongate member has at least one mount that is integrally secured to the wall so that an outer surface of the mount is generally flush with the exterior surface of the wall. A passage is defined by the mount and positioned inboard of the exterior surface of the wall and isolated from the interior cavity of the at least one elongate member. A rib extends over the passage of the mount and defines an entrance and an exit of the passage. 
     Another aspect of the invention that is usable with one or more of the features of the aspects described above includes a bicycle frame assembly having a plurality of tubes that define a bicycle frame assembly. At least one of the plurality of tubes has a hollow portion that is defined by a wall having an exterior surface that faces atmosphere and an interior surface that faces the hollow portion of the tube. A passage having a first opening and a second opening that are both at least generally flush with the exterior surface of the tube is formed in the tube. The passage extends inboard of the exterior surface of the tube and is fluidly isolated from the hollow portion of the tube. A connector passes through the passage between the first opening and the second opening and secures a supplemental structure to the bicycle frame assembly. 
     Another aspect of the invention that is useable with one or more of the features of the above aspects discloses a method of forming a bicycle structure. A mold is provided that has a first mold half and a second mold half that cooperate to define a cavity that defines a majority of an exterior surface of a hollow finish part when the mold is closed. An insert is provided that cooperates with at least one of the first mold half and the second mold half and is positioned in the cavity when the mold is closed. The insert defines a passage and a bridge. The passage extends through the finish part and is defined by a partition that separates an interior volume of the hollow finish part from the passage and from atmosphere and the bridge defines an inlet and an outlet of the passage. Removal of the hollow finish part from at least one of the first mold half and the second mold half exposes the inlet and outlet to atmosphere such that the inlet and outlet are separated from one another by the bridge and are flush with the exterior surface of the hollow finish part. 
     It is appreciated that the aspects and features of the invention summarized above are not limited to any one particular embodiment of the invention. That is, many or all of the aspects above may be achieved with any particular embodiment of the invention. Those skilled in the art will appreciate that the invention may be embodied in a manner preferential to one aspect or group of aspects and advantages as taught herein. These and various other aspects, features, and advantages of the present invention will be made apparent from the following detailed description and the drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The drawings illustrate preferred embodiments presently contemplated for carrying out the invention. 
         FIG. 1  is an elevational side view of a bicycle having a frame that includes a number of mount supports according to the present invention; 
         FIG. 2  is a plan view of one of the mount supports shown in  FIG. 1  with an open flexible connector in the form of a cable or zip tie engaged with the mount support; 
         FIG. 3  is a cross section view of the mount support shown in  FIG. 2  and taken along line  3 - 3 ; 
         FIG. 4  is a view similar to  FIG. 3  and shows the cross section of the bicycle frame member and an elongate control element secured to the frame member via cooperation of the flexible connector and the mount support; 
         FIG. 5  is a cross section view of the mount support shown in  FIG. 2  and taken along line  5 - 5  in  FIG. 3 ; 
         FIG. 6  is a cross section view similar to  FIG. 4  of another embodiment of a structural member of the bicycle shown in  FIG. 1  with an accessory mount secured to the bicycle by a pair of support mounts; 
         FIG. 7  is a schematic plan view of a molding system usable to form the bicycle frame shown in  FIG. 1 ; and 
         FIG. 8  is a cross section view of the mold system shown in  FIG. 6  and taken along line  8 - 8 . 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
       FIG. 1  shows a bicycle assembly or simply a bicycle  10  equipped with a number of mount supports or simply mounts  12  that is constructed in accordance with the present invention. Bicycle  10  includes a frame  14  that includes a number of structural members that are disposed between a seat  15 , handlebars  16 , pedals, and wheels of bicycle  10 . As used herein, the structural members of bicycle  10  can include one or more of what is commonly referred to as a top tube, a head tube, a down tube, a seat tube, one or more seat stays, one or more chain stays, and one or more fork legs. It is appreciated that the present invention is generally applicable to any portion of bicycle assembly  10  wherein a compact and robust mount is desired to be positioned. 
     Still referring to  FIG. 1 , a seat clamp  18  is engaged with an underside  19  of seat  15  and cooperates with a seat post  20  that slidably engages a seat tube  22  of frame  14 . A top tube  24  and a down tube  26  extend forwardly from seat tube  22  to a head tube  28  of frame  14 . Handlebars  16  are connected to a steerer tube  30  that passes through head tube  28  and engages a fork crown  32 . A pair of forks  34 ,  35  extend from generally opposite ends of fork crown  32  and are constructed to support a front wheel assembly  36  at an end thereof or fork tip  38 . Fork tips  38  engage generally opposite sides of an axle  40  that is constructed to engage a hub  42  of front wheel assembly  36 . A number of spokes  44  extend from hub  42  to a rim  46  of front wheel assembly  36 . A tire  48  is engaged with rim  46  such that rotation of tire  48 , relative to forks  34 , rotates rim  46  and hub  42 . 
     A rear wheel assembly  56  is positioned generally concentrically about a rear axle  64 . A seat stay  65  and a chain stay  66  offset rear axle  64  from a crankset  68 . Crankset  68  includes pedals  70  that are operationally connected to a flexible drive such as a chain  72  via a one or more variable diameter chain rings or sprockets  74 . Rotation of chain  72  communicates a drive force to a gear cluster  78  having at least one drive gear that is driven by rotation of chain  72 . Like crankset  68 , gear cluster  78  can include one or more generally concentrically orientated variable diameter gears. 
     Gear cluster  78  is operationally connected to a hub  80  associated with a rear tire  69  of rear wheel assembly  56 . A number of spokes  82  extend radially between hub  80  and a rim  81  that supports tire  69  of rear wheel assembly  56 . As is commonly understood, rider operation of pedals  70  drives chain  72  thereby driving rear tire  69  which in turn propels bicycle  10 . It is appreciated that bicycle  10  could be provided in either of a road bicycle of mountain or off-road or trail bicycle configuration. It is appreciated that each configuration includes features generally directed to the intended operating environment of the bicycle. For example, trail bicycles generally include more robust suspension and tire systems than road bicycles. It is further appreciated that mount supports according to the present invention are equally applicable to stationary bicycles and/or other vehicles or devices configured to support a seated rider and constructed for generally cyclic and/or repeatable movement of a user&#39;s legs whereby user manipulation of various levers alters operation of the underlying vehicle. 
     Bicycle  10  includes one or more operating levers  90  that are supported by handlebars  16 . Levers  90  are operationally connected to one or more of a front wheel brake system  92 , a rear wheel brake system  94 , a front or crankset shift mechanism or front derailleur  96 , and a rear wheel or cassette derailleur  98 , via one or more elongated control elements  100 . As described above, operation of brake systems  92 ,  94  causes interaction of brake pads with the respective wheel assembly  36 ,  56  to slow bicycle  10 . Although brake systems  92 ,  94  are both shown as what is commonly understood as a rim brake, it is envisioned that the present invention is equally applicable to disk brake systems which commonly have a disk and caliper positioned nearer the respective hub  42   64  of a corresponding wheel assembly  36 ,  56  than to the corresponding rim  46 ,  81 . 
     As also alluded to above, one or more levers  90  are also operationally connected to front derailleur  96  and/or cassette derailleur  98  to effectuate a desired shifting between the respective gears of either the various gears of crankset  68  and/or rear wheel gear cluster or cassette  78 . As is commonly understood, lateral translation of the respective derailleur  96 ,  98 , as determined from a plane of rotation of the corresponding gear set, biases the flexible drive member or chain  72  in a lateral direction or in a direction for operational interaction with a respective adjacent gear. As previously explained, handlebars  16  can be provided with any number of single function or multiple function lever assemblies to effectuate the shifting and braking of the underlying bicycle  10 . That is, some lever assemblies are operational in multiple directions and/or support multiple discrete operators that and be manipulated by the hands of the rider to effectuate a desired crankset or cassette shifting operation and/or a front wheel or rear wheel braking operation. Regardless of the configuration of the lever, elongate members  100  communicate the input signal to the respective braking and/or shifting system to effectuate the desired manipulation of the respective system. As explained further below, although elongate signal conductors or elongate members  100  are disclosed as being a sheathed cable, it is envisioned that mount supports  12  are useable with other elongate members and/or for securing other bicycle accessory or ancillary systems relative to the rigid frame members to the bicycle assembly. 
       FIG. 2  is a plan view of one of mounts  12  shown in  FIG. 1  with a flexible fastener or connector, such as a cable tie or zip tie  102 , engaged with mount  12 . Referring to  FIGS. 2-5 , bicycle frame member  24  includes a wall  104  that generally defines the elongate shape of frame member  24 . Wall  104  separates an interior cavity  106  of frame member  24  from atmosphere  108 . Each mount support  12  includes a passage  110  that is defined by a partition  112  that fluidly separates passage  110  from cavity  106  of frame member  24 . A rib or bridge  114  extends over passage  110  thereby defining an inlet or entrance  116  and an outlet or exit  118  of passage  110 . 
     As best shown in  FIGS. 3 and 4 , entrance  116 , exit  118  and bridge  114  are at least generally, and preferably flush with an exterior surface  120  of frame member  24  as defined by the outside surface of wall  104 . Partition  112 , bridge  114 , and wall  104  of mount support  12  and frame member  24  cooperate in such a manner that entrance and exit  116 ,  118  of passage  110  are fluidly exposed to atmosphere  108  while maintaining a fluid isolation of passage  110  from cavity  106  as defined by an interior surface  122  of wall  104  and an interior facing surface  124  of partition  112 . An exterior facing surface  126  of partition  112  faces an interior facing surface  128  of bridge  114 . Surface  126  acts as a guide when fastener  102  is passed therethrough. It is further appreciated that fastener  102  could be first introduced to either of entrance or exit  116 ,  118  and retrieved from the other of entrance or exit  116 ,  118 . 
     Still referring to  FIGS. 2-4 , flexible connector  102  includes an elongate body  130  having an elongate rack portion  132  and a head portion  134 . As is commonly understood, head portion  134  includes a passage or opening  136  that is constructed to slidably receive rack portion  132  of flexible connector  102 . A distal end  138  of flexible connector  102  passes through opening  136  such that a number of teeth or a rack  140  integrally formed on rack portion  132  adjustably cooperate with a ratchet  142  associated with head portion  135  and positioned for interfering engagement with opening  136 . 
     As shown in  FIGS. 3 and 4 , elongate portion  132  of fastener  102  slidably cooperates with passage  110  of mount support  112 , indicated by arrow  146 , such that opposite ends  148 ,  150  of the flexible connector  102  extend beyond entrance  116  and exit  118  of mount support  112 . Passage of rack portion  132  through head portion  134  allows flexible connector  102  to define a closed loop wherein rack portion  132  cannot translate in a loosening direction, indicated by arrow  150 , relative to head portion  134 , but can translate in a tightening direction, indicated by arrow  152 , to allow secure and compact connection of ancillary frame structures, such as an elongate control element like a brake or shift cable  100 , relative to frame member  24 . 
     As shown in  FIG. 4 , elongate control element  100  includes a sheath  154  and an operating cable  156  that extends through the sheath. Hand and/or tool tightening of flexible connector  102  provides a secure contact engagement of elongate control member  100  with respect to an exterior surface  158  of bridge  114 . Trimming of a distal portion  160  of flexible connector  102  provides a secure, compact, and unobtrusive mounting arrangement of the elongate control member  100  relative to the underlying rigid structure of bicycle  10 . The generally flush configuration of entrance  116 , exit  114  and partition  114  of mount support  12  provides an mounting structure for systems ancillary to the frame but desirable for bicycle operation that is unobtrusive relative to the exterior surface  120  of frame member  24 . Furthermore, the ready availability and toolless operability of fastener or flexible connector  102  allows expedient interaction with the mounting system by users intending to reconfigure, replace, and/or otherwise repair accessories or other ancillary systems that are secured to bicycle  10  The relatively compact orientation of the elongate control member  100  relative to exterior surface  120  of frame member  124  also mitigates unintended and/or undesired interference and/or interaction with the elongate control member  100 . 
       FIG. 6  shows another embodiment of the present invention. As shown in  FIG. 6 , a bicycle frame member  160  includes a first mount support  159  and a second mount support  161  that are located at a common cross-section of frame member  160 . First and second mount supports  159 ,  161  are constructed in the same manner as mount support  12 . A partition wall  162  isolates a passage  164  of each mount support  159 ,  161  from an interior cavity  166  of frame member  160 . A bridge  168  extends in a transverse direction relative to a longitudinal axis of passage  164  and defines a respective entrance  170  and exit  172  of each passage  164 . Entrance  170 , exit  172 , and an exterior surface  174  of each mount support  159 ,  161  are generally and preferably flush with an exterior surface  176 , defined by wall  178 , of frame member  160 . Such a construction provides secure and non-aerodynamically detrimental mount support regardless of whether in elongate control element  100 , as shown in  FIG. 4 , or a supplemental or ancillary bicycling accessory or accessory mount  180 , is secured to the underlying frame member  160 . 
     Still referring to  FIG. 6 , accessory mount  180  includes a chamber  182  configured to snap fittingly receive one or more bicycle related accessories and/or supplemental systems. It is appreciated that accessory mount  180  could have virtually any shape and/or can be configured to cooperate with any number of bicycle related accessories such as air pumps, water bottles, water bottle cages, accessory packs, or like. Accessory mount  180  includes a first passage or opening  186  and a second passage or opening  188  that are generally aligned with the overlapping or interacting ends of a flexible connector  190 , such as a zip tie or cable tie, as described above. Regardless of the ancillary structure engaged with the support mount  12 ,  159 ,  160 , simple manipulation of the flexible connector  102 ,  190 , provides secure and compact positioning of ancillary bicycle frame structures relative to the underlying bicycle frame members. 
     Is appreciated that support mounts  12 ,  159 ,  161  could be formed in any of seat tube  22 , top tube  24 , down tube  26 , head tube  28 , one or more seat stays  65 , one or more chain stay  66 , handlebars  16 , and/or one or more of fork legs  34 ,  35  of bicycle assembly  10 . As explained further below, it is also appreciated that support mounts  12 ,  159 ,  161  could be formed in bicycles constructed of a number of materials such as metal frame members, aluminum frame members, carbon fiber frame members and/or combinations thereof. It is further appreciated that support mounts  12 ,  159 ,  161  could be formed in virtually any of the circumferential area associated with walls  104 ,  128  of the respective frame member. It is further appreciated that support mounts  12 ,  159 ,  161  could be disposed at virtually any position along the longitudinal length of the respective frame member and/or that one or more support mounts  12 ,  159 ,  161  can be formed at respective cross-sectional positions of a respective frame member. That is, it is envisioned that bicycle  10  be provided with support mounts  12 ,  159 ,  161  that are positioned anywhere along the structural members of bicycle  10  and in varied quantities and discrete longitudinal and circumferential locations to facilitate securing ancillary structures, accessories, or accessory mount structures to the underlying bicycle so as to reduce the developmental, manufacturing, and service considerations associated with maintaining the operability of the underlying bicycle. 
       FIGS. 7 and 8  show an exemplary molding system envisioned for forming one or more of the generally rigid frame members of bicycle  10 . The mold  200  includes a first mold half  202  and a second mold half  204  that cooperate with one another to define a majority of the cavity  206  associated with a finish shape part  210 . Referring to  FIG. 7 , it should be appreciated that mold cavity  206  defines a combined top tube  14 , head tube  28 , and down tube  26  of the bicycle frame assembly. Understandably, mold  200  could be provided in any number of shapes to form the discrete or combined rigid structures of bicycle  10 . 
     Mold  200  includes a bladder or otherwise collapsible or removable core  208  that is shaped to define the interior cavity  106  of the bicycle frame member. As shown in  FIG. 8 , an insert  212  having a generally curvilinear arm  214  that defines passage  110  associated with a mount support  12 ,  159 ,  161  is disposed in mold  200 . Insert  212  and arm  214  also cooperate to define bridge  114  and a portion  220  of insert  212  forms a portion of an exterior surface  120  associated with wall  104  in the finished part. Such a configuration ensures a generally smooth transition between the wall of the frame member and the area associate with mount support  12 ,  159 ,  160 . Alternatively, it is envisioned that arm  214  cooperate with mold  200  in a retractable manner relative to at least one of first mold half  202  and/or second mold half  204  such that the arm  214  may be retracted from the passage formed in the finished part prior removal of the finish part from mold  200 . 
     Preferably, frame  14  and mount support  12  are concurrently formed of a carbon fiber material. Is readily appreciated that there are a number of methods of producing such a frame assembly such as including various carbon fiber layups introduced of the mold prior to closure of the mold and/or injection of carbon fiber materials prior to and/or after closure of the mold. It is further envisioned that mount supports  12 ,  159 ,  161  be formed in bicycle frame assemblies constructed of other materials such as steel, aluminum, or metal based frame assemblies. Regardless of the underlying material construction of frame  14 , mount supports  12 ,  159 ,  161  provide an integral and non-obtrusive mount support location that is generally flush with an exterior surface of the finished part and does not require supplemental cooling, machining, and/or conditioning of the mount support  12  for use with the underlying bicycle and/or ancillary or accessory systems. 
     Therefore, one embodiment of the invention includes a bicycle assembly having a plurality of elongate members that are connected and form a top tube, a head tube, a down tube, a seat tube, at least one chain stay, at least one seat stay, and at least one fork leg. At least one of the plurality of elongate members includes a hollow tube that is defined by a wall having an exterior surface and an interior surface that faces an interior cavity bounded by the wall. The at least one elongate member has at least one mount that is integrally secured to the wall so that an outer surface of the mount is generally flush with the exterior surface of the wall. A passage is defined by the mount, positioned inboard of the exterior surface of the wall, and isolated from the interior cavity of the at least one elongate member. A rib extends over the passage of the mount and defines an entrance and an exit of the passage. 
     Another embodiment of the invention that is combinable with the other embodiments includes a bicycle frame assembly having a plurality of tubes that define a bicycle frame assembly. At least one of the plurality of tubes has a hollow portion that is defined by a wall having an exterior surface that faces atmosphere and an interior surface that faces the hollow portion of the tube. A passage having a first opening and a second opening that are both at least generally flush with the exterior surface of the tube is formed in the tube. The passage extends inboard of the exterior surface of the tube and is fluidly isolated from the hollow portion of the tube. A connector passes through the passage between the first opening and the second opening and secures a supplemental structure to the bicycle frame assembly. 
     Another embodiment of the invention that is combinable with one or more of the above embodiments includes a method of forming a bicycle structure. A mold is provided that has a first mold half and a second mold half that cooperate to define a cavity that defines a majority of an exterior surface of a hollow finish part when the mold is closed. An insert is provided that cooperates with at least one of the first mold half and the second mold half and is positioned in the cavity when the mold is closed. The insert defines a passage and a bridge. The passage extends through the finish part and is defined by a partition that separates an interior volume of the hollow finish part from the passage and from atmosphere and the bridge defines an inlet and an outlet of the passage. Removal of the hollow finish part from at least one of the first mold half and the second mold half exposes the inlet and outlet to atmosphere such that the inlet and outlet are separated from one another by the bridge and are flush with the exterior surface of the hollow finish part. 
     The present invention has been described in terms of the preferred embodiments, and it is recognized that equivalents, alternatives, and modifications, aside from those expressly stated, are possible and within the scope of the appending claims. It is further appreciated that the respective features of any one of the embodiments discussed above is not necessarily solely exclusive thereto.