TWI627056B - Method for the manufacturing of a rim,the rim so manufactured,a running wheel including the rim and a bicycle having the running wheel - Google Patents

Abstract

The invention relates to a method for manufacturing a rim 1 having a material layer structure for use in a muscle-powered vehicle, the method comprising: a) providing a first mold 2 resistant to pressure and high temperature; Inserting a first planar reinforcing fiber component 10 into the first mold 2, the first planar reinforcing fiber component 10 being composed of at least two separate layers of reinforcing fiber material; c) one or more reinforcing fiber mats 11 , 12, 13, inserted into the first mold 2, positioned on the first planar reinforcing fiber component 10; d) inserting a second planar reinforcing fiber component 14 into the first mold 2, in the On the one or more reinforcing fiber mats 11, 12, 13, the second planar reinforcing fiber assembly 14 is composed of at least two separate layers of reinforcing fiber material; e) inserting a spacer 16 into the first mold 2; Place a sharp edge auxiliary contour layer 15 on the spacer 16 so that the previously formed material layer surrounds the auxiliary contour layer 15; f) close the first mold 2 with a compressive and high temperature resistant second mold 3 ,and g) Hardening The layer structure of the material containing the reinforcing fibers obtained by the previous step, opening the first and/or second molds 2, 3, and taking out the obtained rim 1 .

The invention also discloses a rim made according to the method, a running wheel made according to the method, and a bicycle having a running wheel or rim according to the invention.

Description

A method for making a rim, the rim obtained by the method, comprising the Running wheel of the rim and bicycle with the running wheel

The present invention relates to a method of making a rim having a material layer structure and for use in a muscle powered vehicle, such as a bicycle.

A known method of manufacturing a rim is described in the German patent application DE 10 2007 042 198 A1. This patent proposes a method of manufacturing a rim ring for the manufacture of rims, in particular nipper rims.

The method described therein comprises the steps of providing a rim profile made of a cured composite fiber material, providing a plastic forming element, providing at least one cover layer made of a composite fiber material, the plastic molded component along the diameter The insert is inserted into the rim contour and the cover layer is positioned relative to the plastic forming element and the rim contour such that at least a portion of the cover layer extends from the plastic forming element to the outside of the rim contour. The earlier document described above also relates to a method of attaching spokes made of composite fiber material to a rim ring. The earlier document also relates to a rim ring, a clinch rim and a bicycle comprising the nipper rim.

Furthermore, WO 2011/096805 A1 also discloses an apparatus and method for producing a reinforced fiber product. This document discloses in particular a toroidal reinforced fiber composite article.

The rim has been used in vehicles for a long time to support the tires. Such rims can be used in vehicles driven by internal combustion engines, such as automobiles, trucks or other utility vehicles, but can also be used in muscle powered vehicles, such as bicycles.

In the field of bicycles, operators have attempted to make rims using a variety of different materials, such as so-called aluminum alloy rims, steel rims, titanium alloy rims, and so-called composite rim/composite rims. The composite rim described above can generally be understood as a rim comprising different materials. One particular form of such a composite rim is a fiber composite rim, that is, a rim made of reinforced fibers, such as staple fibers or long fibers. The fibers are typically embedded in a resin. The resin is hardened during the manufacturing process to provide a fully finished rim. In most processes, one or more finishing steps are required at the end to finish the surface of the rim product, including the reinforced fibers, which is usually ground.

The advantages of fiber composite rims have become apparent over the past 20 years because this type of rim is lighter and stiffer than rims made of materials other than fiber composites. This type of rim can also overcome challenges, especially in high-end applications, such as racing bicycles, triathlon bicycles and mountain bikes.

Unfortunately, the existing fiber composite rims are still too expensive and there is still room for improvement in terms of rigidity and weight.

It is an object of the present invention to solve the above problems to eliminate or at least ameliorate the disadvantages of the above known techniques. In particular, the present invention provides a rim suitable for machining, and a method for making the rim to reduce manufacturing costs and improve the rim to have a rigidity and reduced weight superior to conventional rims.

According to the present invention, the above technical problem is solved by a method comprising the following steps, preferably in accordance with the sequence: a) providing a first mold which may be resistant to pressure and high temperature, for example made of steel alloy a mold, b) inserting a first planar reinforcing fiber component into the first mold, the first planar reinforcing fiber component being composed of at least two separate material layers, each material layer being in the form of, for example, a knitted fabric, a mesh Woven fabric, woven or non-woven fabric, for example comprising glass fibers, aramid fibers and/or carbon fibers, or formed of glass fibers, aramid fibers and/or carbon fibers, c) one or more a reinforcing fiber mat mainly made of reinforced fiber, inserted into the first mold, on the first planar reinforcing fiber component, d) inserting a second planar reinforcing fiber component into the first mold, Above the one or more reinforcing fiber mats, the second planar reinforcing fiber component is composed of at least two separate material layers, each of which is in the form of a knitted fabric, a mesh fabric, a braid Or a non-woven fabric made of, for example, glass fiber, aramid fiber and/or carbon fiber, or formed of glass fiber, aramid fiber and/or carbon fiber, e) inserting a spacer into the first mold f) closing the first mold with a second mold that is resistant to pressure and high temperature, the second mold being made of, for example, a steel alloy, and g) hardening the material layer structure containing the reinforcing fibers obtained by the previously performed steps, for example, by increasing the pressure and/or temperature, opening the first and/or second mold, and taking out the obtained rim.

The above composite layer structure/layer structure can be easily realized by a machine. This method can shorten the production time. Although the weight of the rim is substantially unchanged from the known lightest rim, it is indeed possible to significantly increase its rigidity. The product produced by the present invention has a coefficient of rigidity that far exceeds what is currently available in commercially available products. And since the present invention provides a load regulation design, its convenience characteristics are not deteriorated and improved.

Advantageous embodiments as claimed in the dependent claims of the present invention will be described in detail below.

For example, in an advantageous embodiment of the invention, it is further included that before the step b and/or after the step a, a first continuous double-ply fabric/material is wrapped/bottomed along a line/(spiral) curve/edge/straight line. After the roll, the step of inserting into the first mold. The first continuous double-ply fabric/material is in the form of a knitted fabric, a mesh fabric, a woven fabric or a non-woven fabric, for example, made of reinforced fibers, and is made of, for example, glass fiber, aramid fiber and/or carbon fiber. Or formed from glass fibers, aramid fibers and/or carbon fibers. According to this, a specific orientation of the fibers is oriented/oriented.

In terms of the load capacity of the rim, in an advantageous embodiment of the invention, it is additionally included before step f and/or after step e, using a second continuous double-ply fabric along a line/(helix) curve/edge/ After linear wrapping/unwinding, the step of inserting into the first mold over the second planar reinforcing fiber component. The second continuous double-ply fabric/material is in the form of a knitted fabric, a mesh fabric, a woven fabric or a non-woven fabric, for example, made of reinforced fibers, and is made of, for example, glass fiber, aramid fiber and/or carbon fiber. Or formed from glass fibers, aramid fibers and/or carbon fibers.

The spacer may be an inflatable hose such as rubber, natural rubber or a decane hose, or a foamed material such as a polymethacrylimide structure, that is, a polymer. Hardened plastic (PMI) and hardened foam (PMI-E) and belong to polyimide materials, in particular a so-called Rohacell foam, and / or an incompressible plastic part, such as a (thermosetting) resin Components and contain (short) fiberglass. Such an embodiment can achieve/form a particularly precise and loadable rim flange.

In terms of absorption of force, in an advantageous embodiment of the invention, the reinforcing fibers in the first continuous double layup fabric and/or the second continuous double lay fabric are primarily oriented substantially parallel to the circumference of the rim The alignment of the directions, that is, the angle of the circumferential direction is formed by about ±5° or about 0°.

An advantageous exemplary embodiment of the present invention is further characterized in that the reinforcing fibers in the first planar reinforcing fiber component and/or the second planar reinforcing fiber component mainly have a substantially aligned circumferential direction orthogonal to the rim The arrangement, i.e., the circumferential direction, forms an included angle of from about 80° to about 100°, preferably 85°, 90° or 95°. This design makes it possible to produce a rim that is particularly loadable and rigid in its axial direction.

In a suitable embodiment of the invention, the first planar reinforcing fiber component and/or the second planar reinforcing fiber component (each) have three layers of material separated from each other at least in the axial direction, in the form of, for example, reinforcement. a knitted fabric, a mesh fabric, a woven fabric or a non-woven fabric made of fibers, for example, comprising glass fibers, aramid fibers and/or carbon fibers, or formed of glass fibers, aramid fibers and/or carbon fibers. .

In such an embodiment, a particularly advantageous embodiment is that, among the three layers, the reinforcing fibers of the intermediate layer form an orientation of 95° with respect to the circumferential direction, adjacent to/adjacent The two layers of reinforcing fibers of the intermediate layer have an orientation of 85°. The above orientation may have an allowable deviation of ±1°~2°.

If immediately after step e and/or immediately before step f, a sharp edge auxiliary contour layer is positioned on the spacer and the material layer structure obtained in this step is folded over the auxiliary contour layer / The upper roll/lower fold gives a particularly rigid rim on the side.

In the above embodiment, an advantageous embodiment is that when the auxiliary contour layer is folded/rolled/folded, the axial end of the spacer is folded/rolled/folded, so that The lateral ends of the resulting material layer structure face each other. This design makes it easier for the rim to reach/engage the tire clamp to which the rim is to be secured.

If the axial ends of the material layer structure are overlapped, or a gap is used so as to be constantly spaced apart when viewed in the axial direction in the circumferential direction, the load capacity of the clamp can be increased. This design makes it easier to remove the spacer in this embodiment. In this implementation, the time required for manufacturing can also be shortened.

In order to improve the efficiency of the production, it is advantageous in the present invention that the reinforcing fiber is previously impregnated with a resin such as an epoxy resin, a thermosetting resin or a thermoplastic resin, or "dried" first, and then in another separate step, (The above) resin is saturated.

In an advantageous embodiment of the invention, the first mold is divided at least along its axial direction, for example into two mold halves, and/or the second mold is divided along its circumferential direction to form a mutual The link is preferably divided into three split molds of the same size. This design makes the component's access and the insertion of individual material layers easier.

If the aerodynamic properties of the rim are not important, an advantageous embodiment of the invention is to drill a spoke-connected hole and/or a valve member through-hole on the radially inner side of the rim after or immediately after step g. This design can be made into a particularly lightweight rim.

In order to manufacture a loadable (running) wheel in an efficient manner, an advantageous embodiment of the invention is to connect the first set of spokes to their rims, radially away from the position of the second set of spoke connections, for example two sets The spokes are attached to different layers of the rim.

If a vacuum generation step is performed before or immediately before step f, the individual components can be well positioned with no free movement between them. For this purpose, a cover with a three-part radial sleeve can be inserted. In addition, the same effect can be achieved by covering with a bag.

In order to allow the spacer to be easily removed and at the same time to produce a loadable rim flange, an advantageous embodiment of the invention is to radially outer milling the rim after or immediately after step f To create the flange of the rim. As an alternative to milling, turning can also be used.

In an advantageous exemplary embodiment of the invention, it is also characterized in that the foamed wedge is attached to, for example, an adhesive inner side to the radially inner side, for example by means of an adhesive tape, spiral Way to attach.

In a further advantageous embodiment of the invention, the method further comprises the step of covering the area which later becomes the brake flank, preferably overlying the foaming wedge, in the form of, for example, a knitted fabric, a mesh fabric, a woven fabric or a non-woven fabric. cloth.

In order to provide a good speed measurement or pacing measurement in the future, in an advantageous embodiment of the invention, a (permanent) magnet, a (magnetic) sensor, an RFID wafer, a counterweight and/or a valve tube are inserted into One of the rims or the foaming wedge.

If the foaming wedge and/or the rim are covered by one or more reinforcing fiber mats, and the reinforcing fibers of the reinforcing fiber mat are mainly arranged close to or completely along the circumferential direction, an optimized aerodynamic force can be obtained. Learn the characteristics of the rim and improve its load capacity.

In order to increase the cohesiveness of the prefabricated individual components, an advantageous embodiment of the invention is to secure/coat a reinforcing fiber patch in the area where the spokes of the device are intended.

In an advantageous embodiment of the invention, a piece of impact resistant fibrous sheet, such as a sheet of material made of a thermoplastic material, is positioned in the region of the foaming wedge, preferably on the foaming wedge. Radial center area.

In order to be able to quickly detect the wear of the rim, an advantageous embodiment of the invention is to position and fix an aramid fiber section in the region of (only/just) one of the brake flank. After the circumferential direction of the aramid fiber section, that is to say in the direction of the facet, it is possible to follow another aramid fiber section. In such an embodiment, an advantageous embodiment is that the aramid fiber segments are present only on a single brake flank to avoid unnecessarily increasing weight.

To improve stability, an additional spoke attachment system can be used which is constructed of a spiral fabric/spiral mesh fabric to facilitate insertion of the spokes and/or valve inserts.

In an advantageous embodiment of the invention, in the (resin) soaking step, an increased pressure and/or temperature is used to effect hardening of the (running) wheel.

The invention also relates to a rim for a muscle-powered vehicle, such as a bicycle, having a material layer structure and manufactured in accordance with the method of the invention.

The invention also relates to a (running) wheel having a rim as described above and/or a rim made by the method according to the invention.

Finally, the invention also relates to a bicycle having a (running) wheel as described above, or a rim as described above.

The invention will be described in detail below with reference to the drawings. The drawings show a rim according to a first embodiment of the invention, and a rim made in accordance with the method of the invention.

1‧‧‧ rims

2‧‧‧First mould

3‧‧‧Second mold

4‧‧‧First ring

5‧‧‧second ring

6‧‧‧Axial

7‧‧‧ Radial

8‧‧‧Circumferential direction

9‧‧‧ hollow space

10‧‧‧First planar reinforced fiber component

11‧‧‧Zero reinforced fiber layer/reinforced fiber mat

12‧‧‧Zero reinforced fiber layer/reinforced fiber mat

13‧‧‧Zero reinforced fiber layer/reinforced fiber mat

14‧‧‧Second Plane Reinforced Fiber Assembly

15‧‧‧Auxiliary contour layer

16‧‧‧ spacers

Figure 1 is a cross-sectional view showing only the rim seen across the circumferential direction of the rim shown in the Figure (i.e., in the radial direction). Shown in the figure is the unfinished state before being hardened and removed from the mold. Subsequent processing/dressing may follow.

This drawing is merely illustrative in nature and is only used to facilitate an understanding of the invention. The figure is a superimposed schematic showing the steps performed in sequence, and on the one hand indicates the state in which the rim is placed in the mold, and on the other hand indicates how the individual layers of material are aligned before the mold is closed.

Figure 1 shows a section of a rim 1 according to the invention. The rim 1 is placed above the first mold 2, below the second mold 3. This second mold 3 can also be referred to as a sleeve.

The first mold 2 is divided into a first ring member 4 and a second ring member 5, both of which are disposed on a plane in the circumferential direction and positioned at a position orthogonal to an axial direction. The axis direction 6 is indicated by the arrow labeled 6 in the figure, while the radial direction 7 is indicated by the arrow labeled 7. This circumferential direction 8 is indicated by the arrow labeled 8.

The first mold 2 and the second mold 3 define a hollow space 9 between them, and each material layer in the material layer structure of the rim 1 is inserted and/or positioned in the hollow space 9.

The first planar reinforcing fiber component 10 is first placed/inserted into the first mold 2, so that a piece of the first continuous double-ply fabric can be additionally placed between the two, but the first continuous double-ply is not shown in the figure. Fabric. In the region of the dividing plane between the first ring member 4 and the second ring member 5, axially adjacent to the dividing plane and radially outward at the radially innermost portion of the rim, there is a zero degree reinforcing fiber layer 11 at a certain position Distance separation. Thereafter, a zero degree reinforcing fiber layer 12 and a further zero degree reinforcing fiber layer 13 are formed, followed by an adjacent next radially outer abutting layer, i.e., a second planar reinforcing fiber component 14. The above zero-degree reinforcing fiber layers 11, 12 and 13 may also be referred to as reinforcing fiber mats.

The first planar reinforcing fiber component 10 and the second planar reinforcing fiber component 14 each comprise three layers of layers of reinforcing fiber material separated from one another and each having an orientation of 85°, 95° and 85° angles.

An auxiliary contour layer 15, such as a layer of material made of a sharp edged fiberglass strip, is placed radially outward of a spacer 16. As described in the previous description of the drawings, the distal ends of the zero-degree reinforcing fiber layers 11, 12 and 13 are disposed to surround the axial end faces of the auxiliary contour layer 15, such that the zero-degree reinforcing fiber layers 11, 12 and 13 are far. The ends are in contact with one another, overlapping each other or axially spaced from each other. The resulting state is not shown in the figure.

The first mold 2 and the second mold 3 are composed of a steel alloy component. The reinforcing fiber material of each material layer is carbon (long) fiber.

Claims (11)

A method of making a rim (1) having a material layer structure for use in a muscle-powered vehicle, the method comprising the steps of: a) providing a first mold resistant to pressure and high temperature ( 2); b) inserting a first planar reinforcing fiber component (10) into the first mold (2), the first planar reinforcing fiber component (10) consisting of at least two separate layers of reinforcing fiber material; Inserting one or more reinforcing fiber mats (11), (12), (13) into the first mold (2) on top of the first planar reinforcing fiber component (10); d) a second planar reinforcing fiber component (14) is inserted into the first mold (2) and positioned on the one or more reinforcing fiber mats (11), (12), (13), the second planar strengthening The fiber component (14) is composed of at least two separate layers of reinforcing fiber material; e) inserting a spacer (16) into the first mold (2); f) a second mold resistant to pressure and high temperature ( 3) closing the first mold (2), and g) hardening the material layer structure containing the reinforcing fibers obtained by the previous step, opening the first or second mold (2), (3), and taking out the prepared Rim Characterized by: further comprising, after the step e and/or immediately before the step f, placing an edge-sharp auxiliary contour layer (15) on the spacer (16) to form the material formed in the previous step The step of surrounding the auxiliary contour layer (15). The method of claim 1, further comprising: before step b and/or after step a, inserting a first continuous double-ply fabric made of reinforced fibers, wrapped along a line, and inserted into the first mold The steps in (2). The method of claim 1 or 2, further comprising: before step f and/or after step e, inserting a second continuous double-ply fabric made of reinforced fibers, wrapped along a line, and inserted into the first In a mold (2), the step of positioning over the second planar reinforcing fiber component (14). The method of claim 1, wherein the spacer (16) is designed as an inflatable hose, a foamed material or an incompressible plastic component. The method of claim 2, wherein the reinforcing fibers in the first continuous double-ply fabric have predominantly aligned substantially parallel to the circumferential direction of the rim (1). The method of claim 3, characterized in that the reinforcing fibers in the second continuous double-ply fabric have predominantly aligned substantially parallel to the circumferential direction of the rim (1). The method of claim 1, wherein the reinforcing fibers in the first planar reinforcing fiber component (10) and/or the second planar reinforcing fiber component (14) are substantially aligned substantially orthogonal to the rim (1) Arrangement in the circumferential direction. The method of claim 1, wherein the first planar reinforcing fiber component (10) and/or the second planar reinforcing fiber component (14) has three layers of reinforcing fiber material separated from each other in the axial direction. A rim (1) of a muscle-powered vehicle having a material layer structure and produced according to the method of any one of claims 1 to 8. A running wheel having a rim (1) according to claim 9. A bicycle having a running wheel according to claim 10.