High performance bicycle crank
View Patent ↗A carbon fiber bicycle crank includes an axle lug, having a portion for receiving a crank axle. A foam core is coupled to the axle lug during a first molding process. A pedal engaging lug is coupled to the foam core after the completion of the first molding process, and a carbon fiber composite material exoskeleton is coupled to and disposed exteriorly of the axle lug, foam core and pedal lug.
1. A carbon fiber bicycle crank arm comprising
(a) an axle lug including a portion for receiving a crank axle, wherein the axle lug includes a spider portion, the spider portion comprising at least one radially extending endoskeletal arm having a distal end capable of being coupled to a chain ring, the radially extending arm including an aperture
(b) a foam core coupled to the axle lug during a first molding process
(c) a pedal engaging lug coupled to the foam core after the completion of the first molding process; and
(d) a carbon fiber composite material exoskeleton coupled to and disposed exteriorly of at least a portion of the axle lug, radially extending endoskeletal arm, foam core and pedal lug,
wherein the foam core includes a portion disposed within the aperture of the radially extending arm.
2. The carbon fiber bicycle crank arm of claim 1 wherein the carbon fiber composite material exoskeleton comprises a first sheet-like skin member and a second sheet-like skin member, the first and second skin members being formed into a unitary exoskeleton in a second molding process.
3. The carbon fiber bicycle crank arm of claim 1 wherein the axle lug, foam core and pedal engaging lug create a form for defining the shape of the carbon fiber composite material exoskeleton placed there over.
4. The carbon fiber bicycle crank of claim 1 wherein the foam core includes a generally non-hollow rod portion extending between the pedal engaging lug and the axle lug.
5. The carbon fiber bicycle crank of claim 4 further comprising a ring engaging lug, wherein the rod portion of the foam core includes a recessed portion for receiving the ring engaging lug.
6. The carbon fiber bicycle crank arm of claim 1 further comprising an adhesive member for adhesively coupling the pedal engaging lug to the foam core.
7. The carbon fiber bicycle crank arm of claim 1 further comprising a ring engaging lug disposed exteriorly of the foam core and interiorly of carbon fiber material exoskeleton, the ring engaging lug being capable of being coupled to a chain ring.
8. The carbon fiber bicycle crank arm of claim 7 wherein the spider portion includes at least four radially extending aperture containing arms, and the foam core includes a portion disposed within the apertures of each radially extending arm.
9. The carbon fiber bicycle crank arm of claim 8 wherein the form core includes a recessed portion for receiving the ring engaging lug after completion of the formation of the foam core.
10. The carbon fiber bicycle crank arm of claim 7 further comprising an adhesive member for adhesively coupling the pedal engaging lug to the foam core.
11. A carbon fiber bicycle crank arm comprising
(a) an axle lug including a portion for receiving a crank axle, the axle lug includes a spider portion comprising at least one radially extending arm,
(b) a foam core coupled to the axle lug during a first molding process the foam core engages a portion of the radially extending arm
(c) a pedal engaging lug coupled to the foam core after the completion of the first molding process; and
(d) a carbon fiber composite material exoskeleton coupled to and disposed exteriorly of axle lug, foam core, radially extending arm and pedal lug,
wherein the radially extending arm includes a slotted aperture extending along at least one half of the length of the radially extending arm, and the foam core includes a portion disposed within the slotted aperture.