United States Patent [191 [111 4,437,679

Canipagnolo [45] Mar. 20, 1984

[54] TUBE STRUCTURE FOR BICYCLE AND 3,451,434 6/1969 Bauer ................................ .. 138/172
MOTORCYCLE FRAMES 3,966,230 6/1976 Nicol ............................. .. 280/281 R

1 [76] Inventor: Tullio Campagnolo, Via della

Chimica, 36100 Vicenza, Italy Primary Examiner-Joseph F. Peters, Jr.
[21] Appl. 190.; 365,910 Assistant Examiner-D. Lynn Fugate
Attorney, Agent, or Firm-Young & Thompson
[22] Filed: Apr. 6, 1982
[30] Foreign Application Priority Data
Apr. 15, 1981 [IT] Italy ................................... .. 21177/81
[57] ABSTRACT
Apr. 15, 1981 .. A light and strong tube structure for frames of bicycles
19, 1981 [IT] Italy .................................... .. 22435/81 and motorcycles has its cross sections with a variable
[51] Int. 01.3 ............................................ .. 362K 19/02 thickness of the tube wall. Said wall is formed by two or
[52] US. Cl. .............................. .. 280/281 R; 138/141; more layers of different materials, of which at least one
138/174; l38/DIG. 11 is metallic material and at least another one has a prefer
[58] Field of Search ..... .. 280/281 R, 281 LP, 281 W, ential direction of tensile strength. Preferably, the
280/281 B, 274, 279; 138/140, 141, 143, 153, straight cross sections of the tube are outwardly de?ned
172, 174, 177, DIG. 11; 428/398; 296/205; by a circle and inwardly de?ned by an ellipse and the
244/117 R, 119, 131, 133 said layers comprise an external metallic layer and an
[56] References Cited internal layer of ?bers incorporated into resin.
U.S. PATENT DOCUMENTS
556,805 3/ 1896 Carlson 1 280/279
2,261,912 ll/l941 Buente ............................... .. 138/177 16 Claims, 11 Drawing Figures
U.S. Patent Mar. 20, 1984- Sheet 1 of2 4,437,679

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U.S. Patent Mar. 20, 1984 Sheet 2 of 2 4,437,679
 4,437,679
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forward also turns into a torque tending to cause a
TUBE STRUCTURE FOR BICYCLE AND transversal ?exure in the frame.
MOTORCYCLE FRAMES Thus, the more ?exible the transversal plane of the
frame, the higher the cyclists efforts being wasted, due
BACKGROUND OF THE INVENTION 5 to said passive torque, to the detriment of a successful
The present invention relates to an improved tube performance. In short, the higher the transversal ?ex
structure, particularly a tube structure designed to be 'ure, the lower the cyclists performance. It thus appears
chie?y subject to bending stress and required to be as evident that it is imperative for competition bicycles,
light as possible. and appropriate for normal bicycles and motorcycles,
More speci?cally, the present invention relates to a to be equipped with frames having a high transversal
tube for bicycle and motorcycle frames having im stiffness and therefore with tubes apt to guarantee such
proved characteristics, especially suited for forming high transversal stiffness to the frames, without losing in
frames of competition bicycles with highly distinctive lightness.
features. In view of the aforespeci?ed problems and require
15 ments, the object of the present invention is an im
As known, various types of tubes-easy to be found
on the present market-have been made available by proved tube structure designed to be chie?y subject to
technique for the forming of bicycle and motorcycle bending stress and especially suited for forming frames
of bicycles and motorcycles with highly distinctive
frames. While, for the more common constructions, use features.
is made of simple ordinary cylindrical tubes of uniform '20
thickness, when special frames are constructed-- SUMMARY OF THE INVENTION
wherein a great lightness has to be combined with a
Said tube structure is essentially characterized in that
high rigidity-the following types of tubes are cur its straight cross sections have a variable thickness of
rently used: (a) special steel tubes with reduced uniform the walls of the tube structure. , .
thicknesses; (b) special steel tubes with longitudinally _ Preferably, in said structure, the tube wall is formed
variable thicknesses; (c) light alloy tubes with uniform by two or moreinterconnected layers of different mate
thickness; (d) light alloy tubes of uniform thickness, rials, at least one of them being metallic material and at
with reinforcements in speci?c sections applied by glue least another of them having a preferential direction of
ing inserts. tensile strength; for instance said structure is formed of
In all these types of tubes, each straight cross section a metallic tube lined with a layer of carbon ?bers, posi
has a uniform thickness of the tube wall. tioned longitudinally to the tube (or else distributed in a
It is evident that, in order to improve the characteris helical, or slanting, or interwoven arrangement) and
tics of these tubes, it is necessary to simultaneously incorporated into. an epoxy resin through which they
increase their stiffness and lightness, that is, to work on become integral with said tube.
two characteristics which are inversely proportional More particularly, the present invention relates toa
one in respect to the other: in fact, an increase of the tube structure for bicycle or motorcycle frames, formed
lightness is usually prejudicial to the stiffness, both if by a metallic tube having a section outwardly de?ned
obtained by acting on the proportioning of the parts and by a circle and inwardly de?ned by an ellipse (or oval
if obtained through choice of the materials. Modern curve) with the focuses onto a diameter of said circle,
metallurgy and the expedients adopted in proportioning and by a lining of ?bers incorporated in resin, said lining
and planning the structures have allowed, in recent being applied inside said metal tube and having a section
years, to achieve important progresses, but the require outwardly de?ned by the said ellipse (or oval curve)
ments are increasingly pressing particularly in frames andinwardly de?ned by a second ellipse with the fo
for competition bicycles, wherein stiffness is an essential cuses aligned with those of the ?rst ellipse. ,
element for a proper and lasting response of the ma The present invention also relates to a frame for bicy
chine to the athletes requirements-increasingly tend cles, especially competition bicycles, or for motorcy
ing to reach border-line resultsand wherein lightness cles, obtained by using tube structures as de?ned here
even forms part of the factors which contribute to said above, and more speci?cally to a frame wherein the
border-line results, extolling the performances of the tubes having said structures are all positioned so that
athlete-machine binomial. In the case of motorcycles, their cross sections are arranged with their minimum
the requirements are perhaps less sophisticated, but thickness in correspondence of the plane of the frame.
nonetheless felt, in view of the constructive and ener A frame of this type allows to solve the important
getic problems wherein lightness and stiffness play an problems in the planning of bicycles and motorcycles,
important part, particularly from the economical point mentioned further above and, in particular, the problem
of view. of obtaining in competition bicycles a very high rigidity
In facing the aforementioned problems for the setting transverse to the plane of the frame, combined with a
up of an improved tube structure for bicycle and motor very great lightness (guaranteed by the speci?c weight
cycle frames, the Applicant has discovered that, in said of the tubes forming the frame, which is below that of
frames, the traditional structure of the manufactured 60 the lightest traditional tubes).
article and the components forming said article are apt
to guarantee a high and suf?cient stiffness onthe plane BRIEF DESCRIPTION OF THE DRAWINGS
(vertically and longitudinally to the running direction The invention will now be described in further detail,
of the vehicle) of said frame, whereas transversally to by mere way of example, with reference to the accom
said plane the stiffness never reaches high values. On 65 panying drawings, which show some preferred embodi
the other hand, particularly in bicycle frames, the trans ments thereof and in which:
versal stiffness is of considerable importance, since the FIG. 1 is a straight cross section of a preferred tube
effort made by the cyclist, as well as moving the bicycle structure according to the invention;
 4,437,679
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FIG. 2 is a partly sectioned external view of the pre the plane of the frame does not create any inconve
ferred tube structure of FIG. 1; niences, such rigidity normally exceeding the require
FIG. 3 is a general schematic view of a bicycle frame ments of use, the frame described and'illustrated fully
according to the invention, obtained with tubes having and ef?ciently accomplishes the objects of the inven
the structure of the tube of FIGS. 1 and 2; 5 tion, being to obtain a bicycle frame of great lightness
FIGS. 40 to 4d are straight cross sections along lines and high rigidity, apt to satisfy the strictest require
AA, B-B, C-C, D-D, on a very enlarged scale, ments in the ?eld of cycling competitions.
through the tubes of the frame of FIG. 3; Corresponding advantages are evidently obtained by
FIGS. 5 to 7 are section views of some embodiments producing frames, based on the same principles, for use
of a simpli?ed tube structure according to the invention; in the sports and travelling bicycles found on the mar
and ket, and in motorcycles.
FIG. 8 is a section view of a possible variant of the FIGS'. 5 to 7 of the drawings show the straight cross
preferred tube structure of FIGS. 1 and 2. [sections of some simpli?ed structures of the tube ac
DESCRIPTION OF THE PREFERRED cording to the invention. These structures comprise
15 only the essential characteristic of the invention, that is,
EMBODIMENT
having the wall of variable thickness, with the material
Referring ?rst of all to FIGS. 1 to 4 of thedrawings, concentrated in the areas designed to undergo higher
the tube structure according to the invention is formed stresses and removed from the areas less subject to
(FIGS. 1 and 2) of a metallic tube 2 internally provided stresses, such structures being thus formed of a simple
with a lining 3 of a material having a tensile strength metallic tube, without any lining.
increased longitudinally to-the tube. '
In the embodiment of FIG. 5, the tube structure has a
The tube 2 is preferably made of a light metal, as section outwardly de?ned by a circle 11 and inwardly
aluminium, magnesium or a lightalloy, while the lining de?ned by a circle 13 which is not centered in respect of
3 thereof consists of fibers, preferably carbon ?bers,
positioned either longitudinally, or slanting, or interwo 25 the circle 11, instead of being de?ned by the circle 12
concentric to the outer circle 11. This allows to pre
ven, in respect of the vtube 2 and associated thereto serve the wall thickness of the tube, as planned, there
through a mass of resin, preferably epoxy resin, into
which they are incorporated. T I '
> where the material is subject to highest stress, namely in
As shown in FIG. 1 of the drawing, the tube 2 has its correspondence of the area a, and to progressively re
straight cross section outwardly de?ned by 'alfcir'cle'C 30 duce said thickness towards the diametrally opposed
and inwardly de?ned by an ellipse E centeredv within "area b of minimum thickness, without weakening the
the circle C. The inner lining 3 of the tube 2 is in turn structure and obtaining at the same time a signi?cant
applied with a thickness variable in proportion to that of saving of material (and a consequent considerable light
the tube 1 and its cross section is outwardly defined by ening of the tube), as it appears evident from the area c
the ellipse E and inwardly de?ned by a second ellipse 35 lying'between the curves 12 and 13.
E, centered within the ?rst ellipse. The focuses F-F The embodiment of FIG. 6 similarly provides for two
and F'F' of these ellipses E and E are, as seen, areas a and a of maximum thickness and two areas b
aligned on the diameter Y-Y of the circle C. and b of minimum thickness of the tube wall, these two
In a tube structure as that heretofore described and areas being connectedby arcs of an ellipse 14, centered
illustrated in FIGS. 1 and 2, it has substantially been 40 within the circle 11 which outwardly de?nes the sec
worked in the sense of transferring material from the tion. Also in this case, the reference 12 indicates the
areas crossed by the axis yy of FIG. 1 towards the circle which inwardly defines the section of a corre
areas crossed by the axis x-x of the same ?gure, the sponding conventional tube. It is evident that the struc
maximum thickness of such structure being therefore ture will be apt to stand higher stresses in two areas a
obtained in correspondence of said areas. In this man 45 and a positioned symmetrically. Consequently, a tube
ner, it has evidently been possible to obtain a notable of this type can be usedlike that of FIGS. 1 to
increase in the bending strength of the structurethe 4more frequently and conveniently than the tube of
material employed and, thus, the weight of the tube FIG. 5, and it may be simpler to mount, though evi
being the same-under the action of forces acting on the dently each type of tube will have to be chosen or pre
plane x-x of FIG. 1, or parallel thereto (and tending to ferred according to the use made thereof.
actually bend the structure in said plane), while the In the embodiment of FIG. 7 the tube structure ac
bending strength of such structure is correspondingly cording to the invention has a section with a design
reduced under the action of forces acting on the plane inverted in respect to that of the embodiment shown in
yy of the same ?gure. FIG. 6, in the sense that the said section is outwardly
With tubes having a structure equal or'similar to that de?ned by an ellipse 15 (instead of a circle 16) and
heretofore described and illustrated in FIGS. 1 and 2, inwardly de?ned by a circle 17, centered in respect of
one forms the bicycle frame according to the invention, the ellipse 15. While from the structural point of view
shown in FIGS. 3 and 4. Insaid frame, the various tubes the differences are negligible, from the point of view of
4, 5, 6, are mounted, in respect of their longitudinal axes external appearance the two tubes are rather different.
and of the plane of the frame being formed, so as to Furthermore, in the tube of FIG. 7, the areas a, a of
position their straight cross sections (as shown in FIGS. maximum thickness appear quite evident from the out
4a to 4d) with their thickest areas arranged at the sides side, which may in certain cases be helpful for mounting
of the frame and their-thinnest parts lying in correspon purposes. This last advantage may of course suggest to
dence of the plane of the frame. apply the shape of the tube section of FIG. 7 to the tube
A frame thus formed possesses-with an equal 65 2 of FIGS. 1 to 4.
weight of the tubes employeda notably higher rigid It is understood that, though the curves 14 and 15 of
ity, transversally to its own plane, than the traditional FIGS. 6 and 7 have been de?ned as ellipses, they could
frames. Since, on the other hand, the reduced rigidity in also-with similar results-be de?ned as oval curves.
 5
4,437,679
6
It is also understood that the tube structures having only on the plane of the sections shown in the ?gures of
the sections illustrated in the heretofore described the drawings, but also longitudinally. Furthermore, it
FIGS. 5 to 7, should be mountedparticularly for may be possible to adopt liriings wherein the ?bers,
forming frames of bicycles or motorcycleswith an instead of being disposed longitudinally, have helical or
accurate positioning, which should correspond to the interwoven arrangements. ~
real needs and should take into account the actual 'As to the methods for manufacturing tube structures
stresses involved and their possible variations, as al such as those being claimed herein, no limitations
ready mentioned for the structure of FIGS. 1 and 2___ should be here set, especially as, considering the mov
forming the frame of FIG. 3. elty of such structures, the problem can probably be
FIG. 8 ?nally shows, by way of indication, one of the 0 faced and solved in many and different ways, or with
many possible modi?cations of the preferred embodi appropriately studied technologies. However, the man
ment of the tube structure according to the invention, ufacturing process suggested to be the .most ef?cient
illustrated in FIGS. 1 to 4. and reliableat the Applicant's state of experiments
According to this modi?cation, the tube structure -and probably the most convenient and advisable, is
comprises a metallic tube 21, the straight cross section meant to be the extrusion process.
of which is de?ned by two non-concentric circles 22 Concerning the materials, it is also evident that no
and 23 and isthus of variable thickness, and an internal limitations exist. Nevertheless, particularly for use in
lining 24 of said tube, consisting of a layer of carbon the construction of frames for bicycles and motorcy
?bers and resin, applied inside the tube 21 and also cles, it seems obvious that the tube structure according
varying in thickness in correspondence of the straight .20 to the invention should be preferably made of special
cross section of the structure. Such layer will have its
steel, or aluminium, or magnesium, or any other of the
maximum thickness in the area b corresponding to the
thickest area a of the tube 21, the section of said layer
most widely spread light alloys having high strength.
being outwardly de?ned by the circle 23 and inwardly It is anyhow understood that any other variant or
de?ned by a circle 25, which is not centered within the 25 modi?cation, which will appear evident to the techni
?rst circle. cians skilled in the art, will have to be considered as
In this modi?ed embodiment, the circles 23 and 25 falling within the scope of the present invention.
I claim: .
and possibly the circle 22 may be replaced by other
?gures, such as preferably ellipses or oval curves, with 1. Light and strong tube structure for frames of bicy
out thereby departing from the scope of the invention. cles and motorcycles, said tube structure having a cross
It is understood that the aforedescribed and illus section having a variable wall thickness wall, said struc
trated tube structures according to the invention have ture being comprised by at least two interconnected
been given by mere way of example and that there may layers of different materials, at least one said layer being
be other practical embodiments of the invention, for metallic and at least another said layer having a prefer
what concerns the geometrical con?gurations of the ential direction of tensile strength.
sections, their relative size proportions, and the materi 2. Tube structure as in claim 1, formed of a metallic
als and positioning of the layers. In particular, as re. tube internally lined with a layer of ?bers, positioned
gards to the shape of the sections, all kinds of modi?ca longitudinally of the tube and incorporated into a resin
tions are possible as to the choice of the geometrical through which they become integral with said tube.
?gures which de?ne the straight cross section of the 40 3. Tube structure as in claim 2, wherein said resin is
tube, as to the manner of reciprocally associating said an epoxy resin.
?gures, as to the choice of the tube wall thicknesses in 4. Tube structure as claimed in claim 2, in which said
said association, and so on. In this way, according to the ?bers are helically arranged.
intended use of the structure and to each speci?c plan 5. Tube structure as claimed in claim 2, in which said
ning or stress problem involved, the designers will be 45 ?bers are interwoven. '
abledepending on their capabilityto realize differ 6. Tube structure as in claim 1, wherein the layer of
ent tube structures, speci?cally suited for the problem material having a preferential direction of tensile
to be solved, but always with the positive advantage of strength is formed of carbon ?bers.
obtaining a stiffness in the frames manufactured re 7. Tube structure as in claim 1, wherein the thickness
sponding to the requirements of use of such frames, > of the layer having a preferential direction of tensile
together with a lightening of the structure which would strength varies in the same direction and proportionally
otherwise be unthinkable if the usual present technolo to that of the metallic layer.
gies were to be adopted. 8. Tube structure as in claim 1, wherein the layer of
Concerning the application of the linings or layers of material having a preferential direction of tensile
materials with a preferential direction of tensile 55 strength is applied to only a portion of the other layers.
strength, it is evident that the wide possibilities of appli 9. Light and strong tube structure for frames of bicy
cation, by means of resin, of the carbon ?bers or of cles and motorcycles, said tube structure having a cross
similar materials, allows to study the tube structures for section having a variable wall thickness, said cross sec
bicycle framescase by case-with the strictest adhe tion being de?ned by two non-concentric circles.
sion to the requirements of construction and perfor 60 10. Light and strong tube structure, the straight cross
mance, and to therefore plan such structures in the most section of which having a variable wall thickness, said
rational manner, thereby obtaining results up to date wall being formed by two or more layers of different
considered unattainable. materials, at least one of them being a metallic tube and
It should be noted that the said linings or layers can at least another one of them comprising a lining of ?bers
also be applied partially or discontinuously, in corre 65 incorporated into resin, said lining having a preferential
spondence of areas or along directions of the only sur direction of tensile strength, characterized in that said
faces of the metallic tube, that is, merely where an in straight cross section of the tube is de?ned by a circle
crease of the tensile strength is required, and this not and by an ellipse.
 4,437,679
7
11. Tube structure as in claim 10, wherein also each of
said layers have straight cross section of variable thick
ness. _
12. Tube structure as in claim 10, wherein said metal
lic tube has a section outwardly de?ned by a circle and
inwardly de?ned by an ellipse with the focuses onto a
diameter of said circle, and wherein the lining of ?bers
incorporated into resin is applied inside said metallic
tube and has a'section which is outwardly de?ned'by
the said ellipse and inwardly defined by a second ellipse,
with the focuses aligned with those of the ?rst ellipse. '
13. Tube structure as in claim 12, wherein the focuses
of said second ellipse do not coincide with the focuses .
of the ?rst ellipse.
. 35.v
45
55
60
65
8
14. Frame for bicycles, especially competition bicy
cles, or for motorcycles, characterized in that it is ob
tained by using tubes having a structure as described in
claim 10.
15. Frame as in claim 14, wherein said tubes are all
positioned so that the cross sections thereof are ar
ranged with their own minimum wall thicknesses in
,correspondence of the plane of the frame.
16. Frame as in claim 14, wherein the tubes are all
positioned so that the diameter of the circle which out
wardly de?nes the section of the metallic tube-con
taining the focuses of the ellipses which inwardly de?ne
the section of the metallic tube and which outwardly
and inwardly de?ne the section of the lining of ?bers
incorporated into resinlies on the plane of the frame.
a ; t 1: a: 1: *
'