GB2368320A

GB2368320A - Non-tension spoke wheel

Info

Publication number: GB2368320A
Application number: GB0102971A
Authority: GB
Inventors: Wai Lop Tong
Original assignee: Dynacraft Industries Inc
Current assignee: Dynacraft Industries Inc
Priority date: 2000-10-27
Filing date: 2001-02-07
Publication date: 2002-05-01
Also published as: GB0102971D0; DE10116071A1; CN1350936A

Abstract

A wheel 10, e.g. a bicycle wheel, is assembled from separate elements including a hub 12, rim 14, flange 18, and at least one spoke 16. The separate elements are manufactured individually and connected together by conventional means such as by welding or rivetting. The spoke, which may be hollow, is connected to the rim via the flange which may have tabs (36, figures 3A and 3B) to engage an interior section of the spoke. The spoke/s resist/s compressive and bending forces experienced in conventionally known tensioned spokes by rigidly maintaining the hub position relative to the rim. A reflector mount (50, figure 6D) may also be welded or rivetted to an inner surface 24 of the rim to allow a reflector to be attached to the wheel.

Description

NON-TENSION SPOKE WHEEL

FIELD OF THE INVENTION The present invention relates to non-tension spoke wheels and especially to non-tension spoke wheels used for bicycles.

BACKGROUND OF THE INVENTION Non-tension spoke wheels are well known in the art, examples of which are commercially available from various manufacturers.

In non-tension spoke wheels, the rim is supported from the hub by spokes that are substantially rigid and resist compressive and bending forces. This is in contrast to conventional tensioned spoke wheels, where the rim is supported from the hub by a plurality of spokes under tension. The net tension of each individual spoke pulls the wheel into an accurate circular configuration, centering and supporting the rim about the hub.

Non-tension spoke wheels possess a number of advantages over conventional tensioned spoke wheels. Non-tension spoke wheels permit the use of more aerodynamically shaped spokes and wheel designs having a higher concentration of mass toward the hub in comparison to conventional tensioned spoke wheels, thereby reducing the amount of force required to move the wheel.

Furthermore, non-tension spoke wheels are more rigid than conventional tensioned spoke wheels, thereby improving the transfer of the force from the rider to the wheel.

However, non-tension spoke wheels are relatively expensive to produce. Current methods of manufacturing non-tension spoke wheels involve forming the wheel as a single piece, including the hub, spokes and rim, such as by molding or forging. Such methods are labor intensive and require a high degree of technical skill.

In addition, such prior art non-tension spoke wheels typically involve the use of expensive materials such as carbon fiber or other composites. Consequently, non-tension spoke wheels generally involve higher manufacturing costs in comparison to tensioned spoke wheels.

Furthermore, because the entire wheel is manufactured as a single piece, individual elements of the wheel cannot be modified without redesigning the manufacturing process for the entire wheel. Consequently, it is costly to change the design of such wheels, such as by modifying the shape of the spokes or the size of the rim.

In addition, because the wheel is formed in a single piece, it is difficult to manufacture wheels in which the individual

elements of the wheel, such as the rim or spokes, are made of different materials than the remainder of the wheel.

Thus, there is a need for a non-tension spoke wheel that can be produced by relatively inexpensive manufacturing methods.

Furthermore, there is a need for a non-tension spoke wheel in which the individual elements of the wheel may be modified without requiring the redesign of the manufacturing process for the entire wheel. Finally, there is a need for a non-tension spoke wheel that is relatively simple to manufacture using different materials for the individual elements of the wheel.

SUMMARY OF THE INVENTION These needs and other needs are satisfied by the present invention, which comprises a non-tension spoke wheel assembled from a separately formed rim, hub, and at least one non-tension spoke and connecting flange. The rim has an outer circumference and an inner circumference, the outer circumference adapted to receive a tire and the inner circumference facing the hub. The connecting flange has a first surface and a second surface, the first surface conforming to the inner circumference of the rim, and the second surface engageable with the non-tension spoke.

The non-tension spoke has a first end and a second end, the first end engageable with the second surface of the connecting flange and the second end conforming to the surface of the hub.

The parts of the non-tension spoke wheel are connected by welding. In an alternate embodiment, the connecting flange is

attached to the rim by rivets, while the remaining parts are connected together by welding.

BRIEF DESCRIPTION OF THE DRAWINGS FIGURE 1 is a side elevation view of the non-tension spoke wheel of the present invention, having connecting flanges attached to the rim by spot welding.

FIGURE 2 is a partially broken, front elevation view of the non-tension spoke wheel illustrated in FIGURE 1.

FIGURE 3A is an exploded side elevation view of the nontension spoke wheel illustrated in FIGURE 1.

FIGURE 3B is a top plan view of a connecting flange illustrated in FIGURE 3A.

FIGURE 3C is a perspective view of the reflector mount illustrated in FIGURE 3A.

FIGURE 4 is a side elevation view of the non-tension spoke wheel of the present invention, having connecting flanges attached to the rim by rivets.

FIGURE 5 is a partially broken, front elevation view of the non-tension spoke wheel illustrated in FIGURE 4.

FIGURE 6A is an exploded side elevation view of the nontension spoke wheel illustrated in FIGURE 4.

FIGURE 6B is a top plan view of a connecting flange illustrated in FIGURE 6A.

FIGURE 6C is a top plan view of a connecting flange washer illustrated in FIGURE 6A.

FIGURE 6D is a perspective view of the reflector mount illustrated in FIGURE 6A.

FIGURE 6E is a top plan view of the reflector mount washer illustrated in FIGURE 6A.

DETAILED DESCRIPTION OF THE INVENTION In accordance with the present invention, a non-tension spoke wheel is manufactured from separately formed rim, hub, spokes and connecting flanges. A wheel manufactured in this manner provides distinct advantages over prior art non-tension spoke wheels which are formed as a single piece, such as by molding or forging.

As depicted in Fig. 1, the non-tension spoke wheel 10 of the present invention comprises a hub 12 connected to a rim 14, through spokes 16 and connecting flanges 18. Hub 12, rim 14, spokes 16 and connecting flanges 18 are all separately formed.

Preferably, the parts of non-tension spoke wheel 10 are made of metal, such as steel or aluminum alloys.

In general, hub 12, rim 14, spokes 16 and connecting flanges 18 have relatively simple shapes that are readily manufactured by conventional means, such as by stamping, bending and cutting.

Non-tension spoke wheel 10 is assembled by connecting these individual parts using conventional means, such as by welding or riveting.

Hub 12 has a generally cylindrical outer surface 20 and contains an axle 22. The design and construction of hub 12 and axle 22 are conventional and are well known in the art. When

used in a bicycle, the design of axle 22 within hub 12 may vary between front and rear wheels, to accommodate the sprocket gear on the rear wheel.

Rim 14 has an inner circumference 24 and an outer circumference 26. Outer circumference 26 is shaped to receive a tire (not shown) and is generally U-shaped in cross-section with curled edges 28, as is well known in the art. In addition, rim 14 may be provided with a hole 29 to accommodate a conventional inner tube stem valve (not shown).

The wheel includes one or more non-tension spokes 16, designed to resist compressive and bending forces, unlike conventional tensioned spokes. In a preferred embodiment, spokes 16 are hollow metal tubes with an outer wall diameter and an- inner wall diameter, and are disposed symmetrically about hub 12, as depicted in Figs. 3 and 6.

Spokes 16 have ends 30 and 32, which are connected to hub 12 and rim 14, respectively. Ends 30 of spokes 16 are shaped to conform to the outer surface 20 of hub 12, and are attached directly to the outer surface 20 of hub 12 by welding.

Ends 32 of spokes 1-6 are attached to rim 14 through connecting flanges 18. In a preferred embodiment, connecting flanges 18 have a base 34 and a pair of tabs 36, as depicted in Figs. 3 and 6. Base 34 has a top surface 38 and a bottom surface 40, each of said surfaces having an area larger than the outer wall diameter of spoke 16 at end 32. Tabs 36 extend outward from top surface 38, generally perpendicularly from base 34. Bottom

surface 40 is shaped to conform to the inner circumference 24 of rim 14.

Base 34 of connecting flanges 18 extends on either side of tabs 36 to form ears 42. Connecting flanges 18 are attached to inner surface 24 of rim 14 by spot welding at ears 42, as depicted in Figs. 1 and 3. In an alternative embodiment, connecting flanges 18 may be attached to the inner circumference 24 of rim 14 by rivets 44 through ears 42, as depicted in Figs.

4,5 and 6. Ears 42 are provided with holes 46 to accommodate rivets 44.

As depicted in Figs. 6A and 6C, washers 43 are inserted between rivets 44 and outer circumference 26 of rim 14 to reduce the stress on rim 14 created by attachment of connecting flanges 18. In a preferred embodiment, washers 43 are shaped to conform to outer circumference 26 of rim 14 and have a pair of holes 45 to accommodate rivets 44. Holes 45 correspond to holes 46 in connecting flanges 18.

Spokes 16 are connected to rim 14 through connecting flanges 18. Tabs 36 are slightly resilient and sized and spaced apart slightly more than the inner wall diameter of spoke 16 at end 32, to frictionally engage and fit tightly against the inner wall of spoke 16, at end 32. Spokes 16 are attached to connecting flanges 18 by inserting tabs 36 within ends 32 of spokes 16, and then welding end 32 to top surface 38 of base 34. Because spokes 16 are connected to rim 14 through connecting flanges 18, spokes 16 are shorter than the radial distance between hub 12 and rim 14, as

measured from the outer circumference of the hub to the inner circumference of the rim.

Non-tension spoke wheel 10 may also be provided with a reflector 48 supported on an L-shaped reflector mount 50 attached to inner surface 24 of rim 14. Reflector mount 50 comprises a first leg 52 and a second leg 54, which together form a roughly 90 degree angle. First leg 52 is shaped to conform with inner surface 24 of rim 14. Second leg 54 is provided with a hole 56 to facilitate attachment of reflector 48 to reflector mount 50, using a screw, nut and bolt, rivet or similar means.

Reflector mount 50 is attached to rim 14 by welding first leg 52 to inner surface 24, such that second leg 54 is oriented toward hub 12. In an alternative embodiment, first leg 52 is attached to inner surface 24 of rim 14 by riveting, as shown in Fig. 6. First leg 52 is provided with a hole 58 to accommodate rivet 60. As depicted in Figs. 6A and 6D, a washer 62 is inserted between rivet 62 and outer circumference 26 of rim 14 to reduce the stress on rim 14 created by attachment of reflector mount 50.

It is presently preferred to treat the exterior and interior surfaces of the inventive non-tension spoke wheel with chemical solutions to remove grease, oil and rust, in order to prepare the wheel surfaces for receiving various coatings, such as an antirust coatings, primer, paint, printing and other finish coats.

Apertures 64 and 66 are provided in connecting flanges 18 and washers 43, respectively, as shown in Figs. 3B, 6B and 6C. In addition, the circumference of rim 14 has holes 68 at each point where spokes 16 are attached, as shown in Figs. 2 and 5. When

wheel 10 is assembled, apertures 64 and 66 in connecting flanges 18 and washers 43 are aligned with holes 68 in rim 14, allowing chemical solutions to flow into the interior of hollow spokes 16 and permitting treatment of the inner wall surfaces of spokes 16.

By forming the wheel parts separately, instead of integrally, the non-tension spoke wheel of the present invention may be assembled using relatively inexpensive, conventional manufacturing techniques and materials, which require less skill and labor than the manufacture of prior art non-tension spoke wheels formed as a single piece. In addition, because the hub, rim, spokes and connecting flanges are formed separately, the design of these parts may be modified individually, without requiring modification of the manufacturing process of the entire wheel, as required in the manufacture of prior art non-tensioned spoke wheels formed as a single piece. A wheel factory, therefore, may mix and match or interchange different spokes and rims, depending upon a customer's request.

It will be apparent to those skilled in the art that changes and modifications may be made in the embodiments illustrated herein, without departing from the spirit and the scope of the invention. Thus, the invention is not to be limited to the particular forms herein shown and described except insofar as indicated by the scope of the appended claims.

Claims

What is claimed is : 1. A wheel comprising a rim, hub, and at least one non tension spoke, wherein: said rim, hub, and non-tension spoke are separately formed; said rim having an outer circumference and an inner circumference, said outer circumference facing away from said hub and said inner circumference facing toward said hub; said non-tension spoke having a first end and a second end, said first end connected to said inner circumference of said rim and said second end connected to said hub.
2. The wheel of claim 1, further comprising a connecting flange, wherein : said connecting flange having a first surface and a second surface, said first surface connected to said inner circumference of said rim, said second surface engageable with said first end of said non-tension spoke; and said first end of said non-tension spoke being connected to said inner circumference of said rim through said connecting flange.
3. The wheel of claim 2, wherein said connecting flange is attached to said inner circumference of said rim by welding.
4. The wheel of claim 2, wherein said connecting flange is attached to said inner circumference of said rim by rivets.
5. The wheel of claim 1, wherein said non-tension spoke is a hollow tube with an opening at said first end, and said

connecting flange extends through said opening at said first end of said non-tension spoke.
6. The wheel of claim 1, further comprising a reflector mount connected to said inner circumference of said rim.
7. A bicycle wheel comprising: a rim ; a hub; at least one spoke extending radially from said hub toward but not as far as said rim; and a flange for each spoke, said flange extending between and connecting said rim and said at least one spoke.
8. The bicycle wheel of claim 7 wherein said flange comprises a base and a pair of tabs extending outwardly from said base, said tabs spaced apart.
9. The bicycle wheel of claim 8 wherein said spokes have an inner wall defining an inner diameter, and wherein said tabs are spaced apart farther than said inner diameter.
10. The bicycle wheel of claim 7 wherein said rim, hub and at least one spoke are separately formed.
11. The bicycle wheel of claim 7, further comprising a separately formed reflector mount connected to said rim.
12. A bicycle wheel comprising: a hub; a rim; at least one hollow spoke having an inner wall and having first and second ends, said spoke connected to said hub at

said second end and extending radially toward said rim, said first end spaced apart from said rim ; and a flange for each spoke, said flange frictionally engaging the inner wall of said spoke at its first end, said flange also connected to said rim.
13. The bicycle wheel of claim 12 wherein said hub, rim, spoke and flange are separately formed, and wherein said spoke is permanently attached to said hub and said flange is permanently attached to said rim.
14. The bicycle wheel of claim 12, further comprising a separately formed reflector mount connected to said rim.
15. A wheel substantially as described herein with reference to and as illustrated in the accompanying drawings.