TW202340015A - A hybrid assembly and a bicycle crank arm assembly - Google Patents

Abstract

An insert undercut is disclosed. The insert is metallic and has a first coefficient of thermal expansion (CTE), the insert comprising an outer wall of a first retaining feature; and an undercut shape formed exterior to the outer wall of the first retaining feature such that there is a groove between the outer wall of the first retaining feature and the undercut shape. A composite component having a second CTE different from the first CTE, wherein the insert including the groove is at least partially within the composite component when the composite component is being formed, such that the difference in the first CTE and the second CTE causes the groove between the outer wall of the first retaining feature and the undercut shape of the insert to contract about the composite component to provide a compression to a portion of the composite component within the groove.

Description

Hybrid components and bicycle crank arm components

This application claims priority to co-pending U.S. Provisional Patent Application No. 63/116,614, filed by Fraser Andrew on November 20, 2020 and entitled "Undercut Inserts" and assigned to the assignee of this application. rights and interests, and the entire disclosure of this U.S. Provisional Patent Application is hereby incorporated by reference.

Embodiments of the present invention generally relate to bicycle components such as crank arms and methods for manufacturing bicycle components.

Typically, metal barrel inserts are co-cured into composite arms that have the characteristics of transferring torque and other loads from one material to another. Metal inserts are used in carbon products to provide a stronger joint for threaded or splined parts. Mechanical features are often used to transfer torque and other loads from one material to another. Composite and metallic materials often have different coefficients of thermal expansion (CTE). Typically, composites have a lower CTE than metal inserts because the composite needs to be cured at a temperature higher than room temperature or typically at the conditions of use around the metal insert, which expands before and during curing of the composite. The part is then cooled after curing or molding. Composite arms/bodies generally do not change size, but metal inserts tend to be smaller in all dimensions. The amount depends on the CTE of the metal insert for the specific material. This change in temperature causes different materials to change size. Typically, the composite retains its original shape while the metal insert shrinks to a smaller size. This shrinkage occurs uniformly across all dimensions of the metal insert. As the insert shrinks, this creates stresses at the joint between the composite and metal. Depending on the bonding conditions at the joint, the insert may completely separate from the composite body. If the insert is not separated from the composite, there will be residual stresses at this joint. Both situations will make the part weaker and unable to withstand higher external loads (such as pedal loads) when in use.

100: crank arm

100a: Right hand drive side crank arm

100b: Left hand crank arm

102:Ontology

104: Spindle insert

106: Pedal insert

108:Axis

11:Bottom bracket shaft

110: first end

112:Second end

114,116:hole

114a: Spindle maintains shape

116a,416: Internal retention characteristics

118,120: Insert axis

12: Pivot point

13:Crank assembly

15:Rear axle

17:Chain tensioner

18:Rear sprocket

19:Chain

202, 202a, 302: undercut

202b:bulge

202t: Teeth

222: Bottom bracket

24:Frame

26:Swing arm

28:Front wheel

30:Rear wheel

31:Crown

310,312: Maintain characteristic cuts

32:Car seat

33:Seat post

34: Front fork assembly

36: Handlebar assembly

36a, 36b: Bottom bracket housing

38:Rear shock absorber assembly

404,406: Additional solid features

414: Department of Xila

50:Bicycle

80: Left hand non-drive side crank assembly

81: Spindle

82: Spindle joint

85:Shaft

90: Right-hand drive side crank assembly

91: chain link

92:Open your mouth

Aspects of the invention are illustrated by way of example and not by way of limitation in the drawings, in which:

Figure 1 is a perspective view of a bicycle according to an embodiment;

Figure 2 is an exploded view of a crank assembly according to an embodiment.

3A is a perspective view of an example of a crank arm with an insert, according to an embodiment.

3B is a cross-sectional view of an example of a crank arm with an insert, according to an embodiment.

4A is a perspective view of an example of a spindle insert for a crank arm, according to an embodiment.

4B is a cross-sectional view of an example of a spindle insert for a crank arm, according to an embodiment.

4C is a cross-sectional view of a spindle insert in a portion of a crank arm body, according to an embodiment.

5A is a perspective view of an example of a pedal insert for a crank arm, according to an embodiment.

5B is a cross-sectional view of an example of a pedal insert for a crank arm, according to an embodiment.

5C is a cross-sectional view of a pedal insert in a portion of a crank arm body, according to an embodiment.

6A is a cross-sectional view of an insert with an angled undercut in a portion of a crank arm body, according to an embodiment.

6B is a cross-sectional view of an insert in a portion of a crank arm body with one or more protrusions thereon, according to an embodiment.

6C is a cross-sectional view of an insert in a portion of a crank arm body with one or more teeth thereon, according to an embodiment.

7 is a cross-sectional view of a pedal insert having one or more protrusions thereon, according to an embodiment.

Figure 8 is a cross-sectional view of an insert having two undercuts, according to an embodiment.

Figure 9 is a top view of an insert with additional retention feature cutouts, according to an embodiment.

Figure 10 is a top view of an insert with additional retention feature cutouts of different geometries, according to an embodiment.

Figure 11 is a top view of a spindle insert with additional robustness features, according to an embodiment.

Figure 12 is a top view of a pedal insert with additional strength features, according to an embodiment.

Unless otherwise stated, the drawings mentioned in this specification are understood to be not drawn to scale.

The detailed description set forth below in conjunction with the appended drawings is intended as a description of various embodiments of the invention and is not intended to represent the only embodiments in which the invention may be practiced. Each embodiment described in this disclosure is provided merely as an example or illustration of the invention and should not be construed as preferred or advantageous over other embodiments. In some instances, well-known methods, procedures, articles and circuits have not been described in detail so as not to unnecessarily obscure aspects of the present disclosure.

Differences in thermal expansion properties between composite and metal parts are often referred to as differential thermal expansion. When the composite material is molded around a cylindrical metal insert at high temperatures, the metal insert takes on a larger shape under the thermal conditions in order to cure the resin. The entire part is then cooled and the metal part shrinks into a smaller shape, while the composite (which has a different coefficient of thermal expansion) tends to maintain the larger shape or close to the hot shape (composites change shape less due to temperature ). Based on these differences in thermal expansion properties, during cooling, the metal part will try to shrink and separate from the composite material, which results in large stresses at the joint between the composite material and the metal part, leading to joint failure. This failure may occur even before design/external loads are applied.

The embodiments disclosed herein provide a number of shape and retention features within the insert such that the different coefficients of thermal expansion of the two materials increase the strength of the joint rather than compromising it.

One embodiment utilizes hook or undercut shaped features on the insert that will provide at least one surface that will attempt to compress the composite after the part cools from solidification. The metal insert shape is designed such that some of the composite material effectively sits within (or around) a portion of the metal insert, so the composite material is compressed by the insert as the structure cools.

[00010] In one embodiment, the insert is partially cylindrical, but also has a portion extending outwardly along the body of the crank to resist torque loads and any other loads encountered. In one embodiment, the design also keeps cross-sectional changes or sharp angle changes in the composite to a minimum, which allows for maximum utilization of the strength of the composite.

In the following discussion, one or more components are molded together to form an inseparable body. In one embodiment, instead of two inserts, one of the two inserts would not be used and a direct connection could be used for that end of the arm.

In one embodiment, the spindle insert refers to a metal part, typically a forged or machined Processed aluminum alloys, titanium alloys, steel, other metal alloys, metals, etc. The spindle can be received using splines or an integrated spindle can be used. An embodiment may also have other features on the insert to transfer loads or position the link, bearing preload collars, self-extracting bolt covers.

In one embodiment, the pedal insert refers to a metal part, typically a forged or machined aluminum alloy, titanium alloy, steel, other metal alloy, metal, etc. Typically, the pedal insert will have standard threads to fit the pedal within the pedal insert.

In one embodiment, the spindle insert is partially enclosed at one end of the composite arm. In one embodiment, the pedal insert is partially enclosed at the end of the composite arm opposite the spindle.

In the discussion below, the composite arms can be a thermoplastic or thermoset matrix with a variety of fiber materials, and can also be used in part or alone, most typically carbon fibers, glass fibers, or other fibers. The purpose of the composite arm is to transfer load from the pedal insert to the spindle insert.

Typically, a crank arm is used to transfer the force generated by the user's legs on the pedals to the chainrings. Force is transferred from the pedals to the crank and then to the chainring to ultimately turn the rear wheel. The crank arms also position the pedals relative to the bike frame, even under harsh loads from obstacles or drops.

In one embodiment, the crank arm typically has a length (between the inserts, eg, between the pedal axle centerline and the spindle centerline) of 155 mm to 175 mm. In one embodiment, the pedal insert will fit within a box volume (LxWxH) of 50mmx30mmx20mm and the spindle insert will have a volume of 70mmx50mmx30mm. Although various lengths, dimensions, measurements, and volumes are provided, these are provided as an example of one embodiment. It should be understood that the present technology may utilize one or more different lengths, dimensions, measurements, and volumes.

In the following discussion, and for the sake of clarity, a bicycle is used as an example vehicle. However, in another embodiment, the undercut insert may be used on one or more of a variety of vehicles, such as, but not limited to, bicycles, e-bikes (electric bikes), mopeds, etc. . In one embodiment, the shape and features of the undercut insert described herein may be used in another composite/metal hybrid part to provide retention features created by the shape of the undercut insert.

Referring now to FIG. 1 , a perspective view of a bicycle 50 is shown according to an embodiment. In one embodiment, the bicycle 50 has a frame 24 with a suspension system, the frame 24 including a swing arm 26, The swing arm 26 is capable of moving relative to the rest of the frame 24 when in use; this movement is allowed in particular by the rear shock assembly 38 . The front fork assembly 34 also provides suspension functionality via a shock absorbing assembly in at least one fork leg.

In one embodiment, bicycle 50 is a full suspension bicycle. In another embodiment, the bicycle 50 has only front suspension and no rear suspension (eg, hardtail). In various embodiments, the bicycle 50 may be a road bicycle, a mountain bike, a gravel bicycle, an electric bicycle (electric vehicle), a hybrid bicycle, a motorcycle, or the like.

In one embodiment, the swing arm 26 is pivotally attached to the frame 24 at a pivot point 12 located above the bottom bracket axis 11 . Although the pivot point 12 is shown at a specific location, it should be understood that the pivot point 12 may be found at different distances from the bottom bracket axis 11 depending on the rear suspension configuration. The use of specific pivot points 12 is provided herein for clarity only. The bottom bracket axle 11 is the center of the pedal and crank assembly 13 . Although the pivot point 12 is shown at a specific location, it should be understood that the pivot point 12 may be found at different locations depending on the rear suspension configuration. The use of pivot point 12 is provided herein for clarity only.

For example, in a hardtail bicycle embodiment, there would be no pivot point 12. In one embodiment of a hardtail bicycle, the frame 24 and swing arm 26 will form a fixed frame.

Bicycle 50 includes a front wheel 28 coupled to front fork assembly 34 via axle 85 . In one embodiment, the front fork assembly 34 includes a crown 31 . In one embodiment, a portion of the fork assembly 34 (eg, the steerer tube) passes through the frame 24 and couples with the handlebar assembly 36 . As such, the fork assembly and handlebars are rotationally coupled to the frame 24, thereby allowing the rider to steer the bicycle 50.

In one embodiment, the bicycle 50 includes a rear wheel 30 coupled to the swing arm 26 at the rear axle 15 . Rear shock assembly 38 is positioned between swing arm 26 and frame 24 to provide resistance to pivoting movement of swing arm 26 about pivot point 12 . Accordingly, the illustrated bicycle 50 includes a suspension member located between the swing arm 26 and the frame 24 that operates to significantly reduce rear wheel 30 impact forces transmitted to the rider of the bicycle 50 .

In one embodiment, the bicycle 50 is driven by a chain 19 coupled to both the crank assembly 13 and the rear sprocket 18 . When the rider pedals, rotational input from the crank arm 100 causes the crank assembly 13 to rotate about the bottom bracket axis 11 . This rotation exerts a force on the chain 19, which transfers the rotational energy generated by the rider to the rear sprocket 18, causing the rear wheel 30 to rotate. Chain tensioner 17 provides a variable amount of tension on chain 19 . The need for chain 19 length changes may be due to the crank assembly that may be located 13 and/or multiple different gears on one or both of the rear sprockets 18 and/or on the bottom bracket axle 11 (where the crank assembly 13 is attached to the frame 24 ) with the rear Changes in chainstays as the distance between axles 15 changes due to suspension articulation.

In one embodiment, the saddle 32 is connected to the frame 24 via a seat post 33 . In one embodiment, seatpost 33 is a drop seatpost.

In one embodiment, bicycle 50 may include one or more active suspension components, sensors, and the like, such as disclosed in U.S. Patent 10,036,443, which is incorporated by reference in its entirety.

Referring now to FIG. 2 , an exploded view of crank assembly 13 is shown in accordance with an embodiment. In FIG. 2 , crank assembly 13 is shown coupled with a portion of bicycle frame 24 . In one embodiment, the bicycle frame 24 includes a bottom bracket housing 36a and a bottom bracket housing 36b.

In one embodiment, crank assembly 13 includes a left-hand non-drive side crank assembly 80 that includes a left-hand crank arm 100b and a spindle 81 that, in one embodiment, includes a spindle joint 82 .

In one embodiment, the crank assembly 13 includes a right-hand drive-side crank assembly 90 that includes a right-hand drive-side crank arm 100a having a spindle receiving interface (such as the spindle insert 104), a chain link having an opening 92 Ring 91 and roller chain 19. In one embodiment, the crank assembly 13 includes additional parts such as pedals, pedal washers, dust boots, spindle spacers, bearings, hex nuts, etc. For clarity, these parts are not shown.

In one embodiment, spindle 81 is coupled with left-hand crank arm 100b, for example, during manufacturing, assembly, maintenance, rebuilding, component replacement, etc. of left-hand non-drive-side crank assembly 80 . In one embodiment, spindle 81 is fixedly coupled to left hand crank arm 100b during manufacture and/or assembly. In one embodiment, spindle 81 and left hand crank arm 100b are manufactured as a single component. In one embodiment, spindle 81 and left hand crank arm 100b are two distinct components that are removably coupled upon assembly.

In one embodiment, for example, during manufacture and/or assembly of the right-hand drive-side crank assembly 90 , the link 13 is coupled with the right-hand drive-side crank arm 100 a. In one embodiment, link 13 is fixedly coupled to right hand drive side crank arm 100a during manufacture and/or assembly. In one embodiment, the chain ring 13 and the right-hand drive side crank arm 100a are manufactured as a single component. In one embodiment, the chain Ring 13 and right hand drive side crank arm 100a are two distinct components that are removably coupled during assembly.

In one embodiment, to install crank assembly 13 into frame 24 of bicycle 50 , spindle 81 is inserted through a portion of bicycle frame 24 (including bottom bracket housing 36 a and bottom bracket housing 36 b ) and an opening in link 13 92. The spindle coupling 82 couples with the pedal insert 106 on the right-hand drive side crank assembly 90 .

During installation of the crank assembly 13 into the frame 24 , one or more bearings (or the like) will be positioned around the main shaft 81 and between the bottom bracket 222 and the bottom bracket before the main shaft 81 is inserted into the frame 24 between housings 36a. Once the spindle 81 passes through the frame 24, one or more bearings (or the like) will be positioned around the spindle 81 and between the pedal insert 106 and the bottom bracket housing 36b. In one embodiment, one or more bearings (or the like) allow rotational movement of spindle 81 within frame 24 while also maintaining spindle 81 fixed and properly oriented within frame 24 .

In one embodiment, some of the components of crank assembly 13 include materials such as aluminum alloys, titanium alloys, steel, other metal alloys, metals, ceramics, and the like. In one embodiment, some of the components of crank assembly 13 include composite materials, such as composites with thermoset or thermoplastic matrices, long or short fiber thermoplastic or thermoset composites, injected carbon fiber, carbon fiber reinforced nylon, carbon fiber reinforced epoxy Resins, glass-filled nylon, compression molding materials, composite plies, chopped carbon fiber, plastics, polymers, long fiber reinforced plastics, short fiber reinforced plastics, etc. In one embodiment, one, some, or all of the components of crank assembly 13 may be formed from a combination of these materials, such as a composite/metal hybrid. Crank components can be manufactured by various methods, such as compression molding, balloon molding, vacuum molding, Resin Transfer Molding (RTM), wire winding, Automated Fiber Placement (AFP), Automated Fiber Placement (AFP), Tape (Automated Tape Laying, ATL), etc.

Referring now to FIG. 3A , one example of a crank arm 100 (which is an example of a drive-side crank arm 100a or a non-drive-side crank arm 100b other than as identified herein) includes a body 102 and a first insert ( For example, spindle insert 104 or pedal insert 106). In one embodiment, crank arm 100 also includes a body 102, a first insert, and a second insert (eg, spindle insert 104 and pedal insert 106). Although currently shown with two inserts (e.g. spindle insert insert 104 and pedal insert 106), but the crank arm 100 may be configured to include a different number of inserts, including, for example, just one insert, or three or more inserts (such as a stringer insert or another additional Structural inserts, etc.).

Body 102 is generally elongated and extends along body axis 108 between first end 110 and second end 112 . In one embodiment, spindle insert 104 is fixedly coupled to body 102 and facilitates coupling to spindle 81 , while pedal insert 106 is fixedly coupled to body 102 and facilitates coupling to a pedal or pedal assembly.

In one embodiment, the body 102 is formed from a body material, and the spindle insert 104 and pedal insert 106 are formed from an insert material, which may be different from the body material. In one embodiment, the body 102 is formed from a composite material including carbon fiber, and the spindle insert 104 and/or the pedal insert 106 are formed from an aluminum alloy. Alternatively, the body 102 may be formed from any other suitable material, including, for example, composite materials including fiberglass, Kevlar, boron or beryllium fibers, or including metals or plastics or polymers. Spindle insert 104 and/or pedal insert 106 may be formed from any suitable material that has the desired strength to support the rotatable connection between the crank arm and other bicycle components, including, for example, aluminum, steel, titanium, other metals and metal alloys, composites and/or polymers or plastics.

In one embodiment, each of spindle insert 104 and pedal insert 106 includes a central hole or aperture configured to receive a fastener (eg, respective hole 114 and hole 116 ). Holes 114 and 116 may be threaded or otherwise configured to mate with corresponding fasteners. In one embodiment, both the spindle insert 104 and the pedal insert 106 extend along respective insert axes 118 and 120 .

In one embodiment, the outer features of the spindle insert 104 and the pedal insert 106 (eg, insert undercuts to maintain shape) are similar in shape. In one embodiment, the external features of the spindle insert 104 and the pedal insert 106 (eg, insert undercut retaining shape) differ from each other.

In one embodiment, the internal features of spindle insert 104 and pedal insert 106 are similar. In one embodiment, the internal features of spindle insert 104 and pedal insert 106 differ from each other. For example, in one embodiment, providing an insert with a differently configured interior, such as a first interior for receiving/coupling the spindle 81 , may help facilitate different types of connections between the crank arms 100 . shaped spindle insert 104, and for receiving/coupling the pedal assembly (with the spindle The inner shape of the shaft insert 104 is different than the inner shape of the pedal insert 106 .

Referring now to FIG. 3B , a cross-sectional view of an example of a crank arm 100 with an insert is shown, in accordance with an embodiment. In FIG. 3B , the cross-section of crank arm 100 includes spindle insert 104 and pedal insert 106 . The features of Figure 3B are similar to the features of Figure 3A, and therefore, for the sake of clarity, discussion of the features shown in Figure 3A will not be repeated.

In one embodiment, crank arm 100 is an elongated "composite body" whose length is several times greater than its width or thickness. In one embodiment, crank arm 100 is made from a thermoset or thermoplastic matrix material and reinforced fiber materials. The center can be hollow or solid. In one embodiment, crank arm 100 has two cylindrical inserts with parallel axes spaced a set distance apart.

In one embodiment, the pedal insert 106 is a metal insert disposed within the composite material used to form the crank arm 100 prior to curing and the composite material curing around the pedal insert 106 to form a single structure. Typically, the pedal insert 106 is used to form a strong joint to attach the pedal to the pedal insert. In one embodiment, the pedals are threaded into the pedal insert 106 . In one embodiment, the metal pedal insert 106 keeps the threads strong and allows for repeated removal and fitting.

In one embodiment, the spindle insert 104 is a metal insert disposed within the composite material used to form the crank arm 100 prior to curing, and the composite material solidifies around the spindle insert 104 to form a single structure. Typically, the spindle insert 104 is used to form a strong joint to attach the spindle and sometimes the link, which is used to transfer loads from the composite body to the spindle or link. In one embodiment, the spindle insert 104 is typically made of a metal or metal alloy to allow for repeated installation and removal of the spindle and link and to allow threaded fasteners/locking rings to be fitted to the spindle insert 104 .

Referring now to FIG. 4A , a perspective view of an example of a spindle insert 104 for a crank arm 100 is shown in accordance with an embodiment. Generally, the spindle insert 104 includes a spindle retaining shape 114a surrounding the bore 114 . To help secure the spindle insert 104 within the body 102 , the spindle insert 104 may include one or more undercuts 202 configured to be embedded in and surrounded by the body 102 .

Typically, undercut 202 (which may be hook-shaped or the like) is formed as part of an insert of composite material including body 102 . In one embodiment, as the metal spindle insert 104 and/or pedal insert 106 cools, the undercut 202 will compress onto the composite body 102 instead of Pull away from composite body 102 . This will create a mating surface between the composite body 102 and the spindle insert 104 and/or pedal insert 106 that is compressed together and will resist pulling apart; thereby allowing the bond between the parts to be stronger and less susceptible to failure. Higher external loads were previously allowed.

In one embodiment, the undercut 202 may be directionally configured to help prevent rotation of the spindle insert 104 relative to the body 102 about the insert axis 118 (shown in FIG. 3A ) and/or to help prevent spindle insertion. Piece 104 translates relative to body 102 along insert axis 118 . For example, the spindle insert 104 (and similarly the pedal insert 106) will have features extending along the long axis 108 of the crank 100 to provide torsional resistance and resistance to other loads that may be encountered.

4B is a cross-sectional view A-A of an example of the spindle insert 104 for the crank arm 100 according to an embodiment. In one embodiment, the spindle insert 104 includes tie-downs 414 (eg, external splines) to position the link 91 , which tie-downs 414 include retention features such as threads, splines, or the like. In one embodiment, the spindle insert 104 includes internal retention features 416 for the locking ring, such as threads or the like. In one embodiment, the spindle insert 104 including the internal retaining features 416 is necessary only for the right-hand drive side crank 100a. In one embodiment, the spindle insert 104 on the non-drive side crank 100b does not require internal retention features 416.

4C is a cross-sectional view A-A of the spindle insert 104 in a portion of the crank arm body 102 according to an embodiment.

Figure 5A is a perspective view of an example of a pedal insert 106 for a crank arm 100, according to an embodiment. Generally, pedal insert 106 includes a generally cylindrical portion surrounding aperture 116 . To help secure the pedal insert 106 within the body 102 , the pedal insert 106 may include one or more undercuts 202 configured to be embedded in and surrounded by the body 102 . Undercut 202 may be directionally configured to help prevent pedal insert 106 from rotating relative to body 102 about insert axis 120 (as shown in FIG. 3A ) and/or to help prevent pedal insert 106 from moving along relative to body 102 . Translates about insert axis 120.

5B is a cross-sectional view of an example of pedal insert 106 for crank arm 100 according to an embodiment. In one embodiment, the pedal insert 106 includes internal retention features 116a such as threads or the like for coupling the pedal with the pedal insert 106 and the undercut 202 .

5C is a cross-sectional view of the pedal insert 106 in a portion of the crank arm body 102 according to an embodiment. In one embodiment, pedal insert 106 includes internal retention features 116a, such as threads, for coupling the pedal to the pedal insert 106 and the undercut 202 to maintain the position of the pedal insert 106 relative to the body 102.

6A is a cross-sectional view of the spindle insert 104 and/or the pedal insert 106 with an angled undercut 202a in a portion of the crank arm body 102, according to an embodiment. In one embodiment, angled undercut 202a is greater than 90 degrees.

6B is a cross-sectional view of the spindle insert 104 and/or pedal insert 106 having one or more protrusions 202b thereon in a portion of the crank arm body 102, according to an embodiment. 6C is a cross-sectional view of the spindle insert 104 and/or the pedal insert 106 in a portion of the crank arm body 102 having one or more teeth 202t thereon, according to an embodiment. Generally, features such as protrusions, ridges, teeth, etc. on one or more surfaces of the spindle insert 104 and/or pedal insert 106 enhance the locking of the spindle insert 104 and/or pedal insert 106 with the body 102 . In one embodiment, features such as protrusions, ridges, teeth, etc. extend circumferentially about the spindle insert 104 and/or the pedal insert 106 .

Figure 7 is a cross-sectional view of a pedal insert 106 (similar to the pedal insert 106 of Figures 5A-5C) having one or more protrusions 202b thereon, according to an embodiment. In one embodiment, one or more protrusions 202b (or other features such as ridges, teeth, etc.) extend parallel to the pedal insert 106 axis. Typically, features such as bumps, ridges, teeth, etc. help lock onto the composite after curing and cooling.

8 is a cross-sectional view of the spindle insert 104 and/or the pedal insert 106 having two undercuts 202 and 302 (eg, two side undercuts) according to an embodiment. In one embodiment, undercuts on both sides provide additional locking and are symmetrical in design. In one embodiment, one or both of undercuts 202 and/or 302 may include additional retention features such as protrusions, ridges, teeth, etc. on one or more surfaces thereof to include the undercut One or both of 202 and 302.

9 is a top view of the spindle insert 104 and/or pedal insert 106 with additional retention feature cutouts 310 according to an embodiment. In one embodiment, retention feature cutout 310 includes one or more slots (or other geometric design) to provide additional surfaces for locking onto. For example, the composite body 102 will be formed or positioned within these retention feature cutouts 312 and the composite material will be bonded together during molding through the retention feature cutouts 312 to couple the spindle insert 104 and/or pedal insert 106 to the body. 102 locked together.

10 is a top view of an insert having additional retention feature cutouts 312 of different geometries, according to an embodiment. In one embodiment, the retention feature cutout 312 includes one or more circular portions (or other geometric designs such as stars, ovals, ovals, etc.) to provide additional surfaces for locking onto. For example, the composite body 102 will be formed or seated in these retention feature cutouts 312 and the composite material will be joined together during molding through the retention feature cutouts 312 to couple the spindle insert 104 and/or pedal insert 106 to the body. 102 locked together.

Figure 11 is a top view of the spindle insert 104 with additional rigidity features 404, according to an embodiment. In one embodiment, the spindle insert 104 may include one or more retention feature cutouts 310 and/or 312 and/or include additional reinforcement features 404 on one or more surfaces of the spindle insert 104 Additional retention features such as bumps, ridges, teeth, etc. In one embodiment, additional strength features 404 provide the spindle insert 104 with an additional amount of surface area in contact with the body 102 to provide additional strength characteristics. Generally, additional strength may be important for vehicles such as mountain bikes, gravel bikes, etc. that will experience greater stresses on the crank arm 100. In one embodiment, the size, shape, surface area, undercut, etc. of the additional stiffening features 406 can be adjusted according to the structural requirements of the crank arm 100 and/or the vehicle to which the crank arm 100 is to be mounted.

Figure 12 is a top view of a pedal insert 106 with additional stiffening features 406, according to an embodiment. In one embodiment, the pedal insert 106 may include one or more retention feature cutouts 310 and/or 312 , and alternatively include additional reinforcement features 406 on one or more surfaces of the spindle insert 104 . Preserve features such as bumps, ridges, teeth, etc. In one embodiment, the additional strength features 406 provide the pedal insert 106 with an additional amount of surface area in contact with the body 102 to provide additional strength characteristics. Generally, additional strength may be important for a vehicle such as a mountain bike, gravel bike, etc. that will experience greater stress on the crank arm 100 than another vehicle such as a road bicycle. In one embodiment, the size, shape, surface area, undercut, etc. of the additional stiffening features 406 can be adjusted according to the structural requirements of the crank arm 100 and/or the vehicle to which the crank arm 100 is to be mounted.

The examples set forth herein are presented in order to best explain, describe the particular application, and thereby enable any person skilled in the art to make and use the described example embodiments. Those skilled in the art will appreciate, however, that the foregoing description and examples are presented for purposes of illustration and example only. The set forth description is not intended to be exhaustive or to limit the embodiments to the precise forms disclosed. Rather, The specific features and acts described above are disclosed as example forms of practicing the claimed scope.

References throughout this document to "one embodiment," "certain embodiments," "implementations," "various embodiments," "some embodiments," "implementations," or similar terms mean that incorporation A particular feature, structure, or characteristic described in this embodiment is included in at least one embodiment. Thus, the appearances of these phrases in various places throughout this specification are not necessarily all referring to the same embodiment. Furthermore, a particular feature, structure, or characteristic of any embodiment may be combined in any suitable manner with one or more other features, structures, or characteristics of one or more other embodiments without limitation.

100a: Right hand drive side crank arm

100b: Left hand crank arm

104: Spindle insert

13:Crank assembly

19:Chain

24:Frame

36a, 36b: Bottom bracket housing

80: Left hand non-drive side crank assembly

81: Spindle

82: Spindle joint

90: Right-hand drive side crank assembly

91: chain link

92:Open your mouth

Claims (21)

A hybrid component consisting of: An insert having a first coefficient of thermal expansion (CTE), the insert comprising: the outer wall of the first retaining feature; and an undercut shape formed outside the outer wall of the first retention feature such that a groove exists between the outer wall of the first retention feature and the undercut shape; and A body having a second coefficient of thermal expansion that is different from the first coefficient of thermal expansion, wherein the insert including the groove is at least partially located when the body is formed. within the body such that the difference in the first coefficient of thermal expansion and the second coefficient of thermal expansion results in the recess between the outer wall of the first retention feature and the undercut shape of the insert A groove contracts about the body to provide compression to the portion of the body within the groove. The hybrid assembly of claim 1, wherein the body is a base portion of a bicycle crank arm, the base portion extends along a body axis and has a first body end and a second body end, the second The body end is axially spaced from the first body end. The hybrid assembly of claim 2, wherein the insert is a spindle insert mounted within the bicycle crank arm at the first body end, the spindle insert being along a spindle insert axis By extension, the spindle insert axis is generally orthogonal to the body axis of the bicycle crank arm. The hybrid assembly of claim 2, wherein the insert is a pedal insert mounted within the bicycle crank arm at the second body end, the pedal insert being along a pedal insert axis By extension, the pedal insert axis is generally orthogonal to the body axis of the bicycle crank arm. The hybrid component as described in request item 2, further including: The insert is a spindle insert mounted within the bicycle crank arm at the first body end, the spindle insert extending along a spindle insert axis, the spindle insert axis being generally orthogonal at the body axis of the bicycle crank arm; and A pedal insert including a groove between the outer wall of the second retaining feature and the undercut shape, the pedal insert being mounted on the second body end at the Within the bicycle crank arm, the pedal insert extends along a pedal insert axis that is generally orthogonal to the body axis of the bicycle crank arm, wherein when the body is formed, the The grooved pedal insert is located at least partially within the body. The hybrid assembly according to claim 1, wherein the insert further includes: a two-sided undercut shape formed outside the outer wall of the first retaining feature such that between the outer wall of the first retaining feature and the two-sided undercut shape There are upper and lower grooves. The hybrid assembly according to claim 1, wherein the insert further includes: At least one opening formed in a portion of the insert external to the outer wall of the first retaining feature, the at least one opening forming a portion of the body about the insert The portion is formed to provide the body with additional faces to lock into. The hybrid assembly according to claim 1, wherein the insert further includes: At least one retaining feature protruding from a portion of the outer wall of the first retaining feature, from the groove or from the undercut shape, the at least one retaining feature protruding from the The body is formed about the portion of the insert to provide an additional surface for the body to lock into. A bicycle crank arm assembly includes: An insert having a first coefficient of thermal expansion (CTE), the insert comprising: the outer wall of the first retaining feature; and an undercut shape formed outside the outer wall of the first retention feature such that a groove exists between the outer wall of the first retention feature and the undercut shape; and a crank arm having a second coefficient of thermal expansion, the second coefficient of thermal expansion being different from the first coefficient of thermal expansion, wherein when the crank arm is formed, the insert including the groove is at least partially within the crank arm such that the difference between the first coefficient of thermal expansion and the second coefficient of thermal expansion results in between the outer wall of the first retention feature and the undercut shape of the insert The groove contracts around the crank arm to provide compression to the portion of the crank arm within the groove. The bicycle crank arm assembly according to claim 9, wherein the crank arm includes: A base portion extending along a body axis and having a first body end and a second body end axially spaced from the first body end. The bicycle crank arm assembly of claim 10, wherein the insert is a spindle insert installed within the crank arm at the first body end, the spindle insert being along the spindle insert An axis extends such that the spindle insert axis is generally orthogonal to the body axis of the crank arm. The bicycle crank arm assembly of claim 10, wherein the insert is a pedal insert installed within the crank arm at the second body end, the pedal insert being along the pedal insert An axis extends such that the pedal insert axis is generally orthogonal to the body axis of the crank arm. The bicycle crank arm assembly as described in claim 10, further comprising: The insert is a spindle insert mounted within the crank arm at the first body end, the spindle insert extending along a spindle insert axis that is generally orthogonal to the the body axis of the crank arm; and A pedal insert including a groove between the outer wall of the second retaining feature and the undercut shape, the pedal insert being mounted on the second body end at the Within the crank arm, the pedal insert extends along a pedal insert axis that is generally orthogonal to the body axis of the crank arm, wherein when the crank arm is formed, the pedal insert axis includes The grooved pedal insert is located at least partially within the crank arm. The bicycle crank arm assembly of claim 9, wherein the insert further includes: a two-sided undercut shape formed outside the outer wall of the first retaining feature such that between the outer wall of the first retaining feature and the two-sided undercut shape There are upper and lower grooves. The bicycle crank arm assembly of claim 9, wherein the insert further includes: At least one opening formed in a portion of the insert exterior to the outer wall of the first retaining feature, the at least one opening being formed in a portion of the crank arm about the insert The portion is formed to provide an additional surface for the crank arm to lock into. The bicycle crank arm assembly of claim 9, wherein the insert further includes: At least one retaining feature protruding from a portion of the outer wall of the first retaining feature, from the groove or from the undercut shape, the at least one retaining feature protruding from the Forming the crank arm around the portion of the insert provides an additional surface for the crank arm to lock into. A bicycle crank arm assembly includes: A plurality of inserts having a first coefficient of thermal expansion (CTE), each insert of the plurality of inserts including: an exterior wall that maintains character; and an undercut shape formed outside the outer wall of the retention feature such that a groove exists between the outer wall of the retention feature and the undercut shape; and a crank arm having a second coefficient of thermal expansion that is different from the first coefficient of thermal expansion, the crank arm comprising: a base portion extending along a body axis and having a first body end and a second body end axially spaced from the first body end, wherein when formed When the crank arm is connected, each of the plurality of inserts including the groove is at least partially located within the crank arm such that the first coefficient of thermal expansion is equal to the second coefficient of thermal expansion. The difference leads to causing each of the grooves between the outer wall of the retaining feature and the undercut shapes of the plurality of inserts to contract about the crank arm to provide support for the crank arm The portion located within each of the grooves provides compression. The bicycle crank arm assembly as claimed in claim 17, further comprising: At least one of the plurality of inserts is a spindle insert mounted within the crank arm at the first body end, the spindle insert extending along a spindle insert axis, the spindle an insert axis generally orthogonal to the body axis of the crank arm; and At least one of the plurality of inserts is a pedal insert mounted within the crank arm at the second body end, the pedal insert extending along a pedal insert axis, the pedal insert The insert axis is generally orthogonal to the body axis of the crank arm. The bicycle crank arm assembly of claim 17, wherein at least one of the plurality of inserts further includes: A two-sided undercut shape formed on the exterior of the outer wall of the retaining feature such that an upper groove is present between the outer wall of the retaining feature and the two-sided undercut shape and lower groove. The bicycle crank arm assembly of claim 17, wherein at least one of the plurality of inserts further includes: At least one opening formed in a portion of at least one of the plurality of inserts external to the outer wall of the retaining feature, said at least one opening forming said providing an additional face for the crank arm to lock into; and At least one retaining feature protruding from a portion of the outer wall of the retaining feature, from the groove, or from the undercut shape, the at least one retaining feature protruding from the crank arm The portion formed about the insert provides an additional surface for the crank arm to lock into. A bicycle, wherein the bicycle includes a hybrid assembly according to any one of claims 1 to 8, or a bicycle crank arm assembly according to any one of claims 9 to 20.

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