Bicycle crank and method for manufacturing said crank

Abstract

A bicycle crank having a casing with first and second ends and a laminated construction of structural fibres incorporated in a thermosetting resin is presented The crank also has first and second inserts, each arranged at a respective end of said casing and are structurally united with said casing by the laminated construction. The inserts connect the bicycle crank to a pedal and to a bottom bracket spindle of a bicycle

1 . A bicycle crank comprising: 
 a casing having a defined length with first and second ends and a laminated construction of structural fibres incorporated in a thermosetting resin; and    first and second inserts, each arranged at a respective end of said casing and structurally united with said casing by the laminated construction, for connecting the bicycle crank to a pedal and to a bottom bracket spindle of a bicycle.    
   
   
       2 . Bicycle crank according to  claim 1 , further comprising a third insert arranged in an intermediate area of said crank.  
   
   
       3 . Bicycle crank according to  claim 1  wherein said structural fibres are chosen from the group consisting of carbon fibres, glass fibres, aramidic fibres, boron fibres, ceramic fibres, and combinations thereof.  
   
   
       4 . Bicycle crank according to  claim 1  wherein said inserts are metallic.  
   
   
       5 . Bicycle crank according to  claim 4  wherein said inserts are made of an aluminum alloy.  
   
   
       6 . Bicycle crank according to  claim 4  wherein said inserts are made of fibre-reinforced plastic material.  
   
   
       7 . Bicycle crank according to  claim 1  wherein the crank further comprises an elongated core.  
   
   
       8 . Bicycle crank according to  claim 7  wherein said elongated core is non-structural.  
   
   
       9 . Bicycle crank according to  claim 8  wherein said elongated core is made of a material chosen from a group consisting of a foam, a wax and a resin.  
   
   
       10 . Bicycle crank according to  claim 9  wherein said elongated core is a preformed body of foamed plastic material.  
   
   
       11 . Bicycle crank according to  claim 1  further comprising union elements for establishing a shape coupling with said inserts.  
   
   
       12 . Bicycle crank according to  claim 11  wherein said elongated core presents end portions and said union elements present recesses for establishing a shape coupling with said inserts and said end portions of said elongated core.  
   
   
       13 . A bicycle crank comprising: 
 an elongated core having first and second ends;    a first insert positioned adjacent to the first end of the core;    a second insert positioned adjacent the second end of the core and a structural fibre fabric incorporated in a thermosetting resin overlaying the core and the first and second inserts,    wherein the inserts are held adjacent to the ends of the core by a respective coupling and the structural fibre fabric which provides a structural connection between the inserts.    
   
   
       14 . The bicycle crank of  claim 13 , further comprising a third insert arranged in an intermediate area of said crank.  
   
   
       15 . The bicycle crank of  claim 13 , wherein said structural fibres are chosen from the group consisting of carbon fibres, glass fibres, aramidic fibres, boron fibres, ceramic fibres and combinations thereof.  
   
   
       16 . The bicycle crank of  claim 13 , wherein said inserts are metallic.  
   
   
       17 . The bicycle crank of  claim 16 , wherein said inserts are made of an aluminum alloy.  
   
   
       18 . The bicycle crank of  claim 13 , wherein said inserts are made of fibre-reinforced plastic material.  
   
   
       19 . The bicycle crank of  claim 13 , wherein said elongated core is non-structural.  
   
   
       20 . The bicycle crank of  claim 13 , wherein said elongated core is made of a material chosen from a group consisting of a foam, a wax and a resin.  
   
   
       21 . The bicycle crank of  claim 13 , wherein said elongated core is a preformed body of foamed plastic material.  
   
   
       22 . The bicycle crank of  claim 13 , wherein said elongated core has end portions configured to be received in recesses of the coupling for establishing a continuous shape including said coupling said inserts said elongated core.  
   
   
       23 . A bicycle crank comprising: 
 a non-structural elongated core having first and second ends;    a first insert positioned adjacent to the first end of the core;    a second insert positioned adjacent the second end of the core; and    a hardened carbon fibre fabric incorporated in a thermosetting resin that forms a structural connection between the inserts.    
   
   
       24 . A bicycle crank comprising: 
 a core of a predetermined length between first and second ends;    first and second inserts, each insert arranged at a respective end of said core; and    a lamination of structural fibres incorporated in a thermosetting resin that structurally unites said core and said inserts in a unified crank structure.    
   
   
       25 . The crank of  claim 24  wherein one insert is configured for connecting to a bicycle pedal and the other insert is configured for connecting to a bicycle bottom bracket spindle.  
   
   
       26 . A bicycle crank comprising: 
 a non-structural core having spaced apart first and second ends;    a first insert positioned adjacent to the first end of the core; 
 a second insert positioned adjacent the second end of the core; and  
 a hardened structure, of carbon fibre fabric fixed in a thermo set resin, that surrounds the non-structural core and connects the inserts.  
   
   
   
       27 . The crank of  claim 26  wherein one insert is configured for connecting to a bicycle pedal and the other insert is configured for connecting to a bicycle bottom bracket spindle.  
   
   
       28 . A bicycle crank comprising: 
 a casing having a defined length with first and second ends comprised of structural fibres arranged in a thermosetting resin; and    first and second inserts, each arranged at a respective end of said casing and structurally united with said casing by the arranged structural fibers, for connecting the bicycle crank to a pedal and to a bottom bracket spindle of a bicycle.    
   
   
       29 . A bicycle crank comprising: 
 a non-structural elongated core having first and second ends;    a first insert positioned adjacent to the first end of the core;    a second insert positioned adjacent the second end of the core; and    structural fibers arranged in a thermosetting resin that, when hardened, form a structural connection between the inserts.    
   
   
       30 . A bicycle crank comprising: 
 a core of a predetermined length between first and second ends;    first and second inserts, each insert arranged at a respective end of said core; and    structural fibres arranged in a thermosetting resin that, when hardened, structurally unites said core and said inserts in a unified crank structure.