US20100301663A1 - Composite fiber bicycle wheels - Google Patents

Composite fiber bicycle wheels Download PDF

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Publication number
US20100301663A1
US20100301663A1 US12/709,178 US70917810A US2010301663A1 US 20100301663 A1 US20100301663 A1 US 20100301663A1 US 70917810 A US70917810 A US 70917810A US 2010301663 A1 US2010301663 A1 US 2010301663A1
Authority
US
United States
Prior art keywords
spokes
flanges
bicycle wheel
sidewalls
wheel
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Abandoned
Application number
US12/709,178
Other languages
English (en)
Inventor
Max Kismarton
Eric Hjertberg
G. Kyle Lobisser
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
DCG WHEELS LLC
Original Assignee
Mad Fiber Inc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Mad Fiber Inc filed Critical Mad Fiber Inc
Priority to US12/709,178 priority Critical patent/US20100301663A1/en
Priority to KR1020117030909A priority patent/KR20120029438A/ko
Priority to JP2012513192A priority patent/JP5622845B2/ja
Priority to CA2800666A priority patent/CA2800666A1/en
Priority to EP14003381.2A priority patent/EP2821331A1/en
Priority to ES10781118.4T priority patent/ES2526988T3/es
Priority to CN201080033301.4A priority patent/CN102458973B/zh
Priority to CN201410189841.1A priority patent/CN104015552A/zh
Priority to AU2010254129A priority patent/AU2010254129A1/en
Priority to EP10781118.4A priority patent/EP2435291B1/en
Priority to PCT/US2010/036155 priority patent/WO2010138557A1/en
Assigned to MAD FIBER, LLC reassignment MAD FIBER, LLC ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: KISMARTON, MAX, LOBISSER, G. KYLE, HJERTBERG, ERIC
Priority to TW99135725A priority patent/TW201129481A/zh
Publication of US20100301663A1 publication Critical patent/US20100301663A1/en
Priority to US13/738,904 priority patent/US20130214586A1/en
Assigned to DCG WHEELS, LLC reassignment DCG WHEELS, LLC ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: MAD FIBER, INC.
Assigned to MAD FIBER INC. reassignment MAD FIBER INC. MERGER (SEE DOCUMENT FOR DETAILS). Assignors: MAD FIBER LLC
Priority to JP2014192847A priority patent/JP2015016863A/ja
Priority to HK15102132.8A priority patent/HK1201498A1/xx
Priority to US15/011,767 priority patent/US9713939B2/en
Abandoned legal-status Critical Current

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60B—VEHICLE WHEELS; CASTORS; AXLES FOR WHEELS OR CASTORS; INCREASING WHEEL ADHESION
    • B60B5/00—Wheels, spokes, disc bodies, rims, hubs, wholly or predominantly made of non-metallic material
    • B60B5/02—Wheels, spokes, disc bodies, rims, hubs, wholly or predominantly made of non-metallic material made of synthetic material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28—Shaping operations therefor
    • B29C70/30—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core
    • B29C70/302—Details of the edges of fibre composites, e.g. edge finishing or means to avoid delamination
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/02—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by a sequence of laminating steps, e.g. by adding new layers at consecutive laminating stations
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60B—VEHICLE WHEELS; CASTORS; AXLES FOR WHEELS OR CASTORS; INCREASING WHEEL ADHESION
    • B60B1/00—Spoked wheels; Spokes thereof
    • B60B1/003—Spoked wheels; Spokes thereof specially adapted for bicycles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60B—VEHICLE WHEELS; CASTORS; AXLES FOR WHEELS OR CASTORS; INCREASING WHEEL ADHESION
    • B60B1/00—Spoked wheels; Spokes thereof
    • B60B1/02—Wheels with wire or other tension spokes
    • B60B1/04—Attaching spokes to rim or hub
    • B60B1/041—Attaching spokes to rim or hub of bicycle wheels
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60B—VEHICLE WHEELS; CASTORS; AXLES FOR WHEELS OR CASTORS; INCREASING WHEEL ADHESION
    • B60B1/00—Spoked wheels; Spokes thereof
    • B60B1/02—Wheels with wire or other tension spokes
    • B60B1/04—Attaching spokes to rim or hub
    • B60B1/043—Attaching spokes to rim
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60B—VEHICLE WHEELS; CASTORS; AXLES FOR WHEELS OR CASTORS; INCREASING WHEEL ADHESION
    • B60B21/00—Rims
    • B60B21/06—Rims characterised by means for attaching spokes, i.e. spoke seats
    • B60B21/062—Rims characterised by means for attaching spokes, i.e. spoke seats for bicycles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60B—VEHICLE WHEELS; CASTORS; AXLES FOR WHEELS OR CASTORS; INCREASING WHEEL ADHESION
    • B60B5/00—Wheels, spokes, disc bodies, rims, hubs, wholly or predominantly made of non-metallic material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/32—Wheels, pinions, pulleys, castors or rollers, Rims
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60B—VEHICLE WHEELS; CASTORS; AXLES FOR WHEELS OR CASTORS; INCREASING WHEEL ADHESION
    • B60B2310/00—Manufacturing methods
    • B60B2310/20—Shaping
    • B60B2310/211—Shaping by folding or bending
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60B—VEHICLE WHEELS; CASTORS; AXLES FOR WHEELS OR CASTORS; INCREASING WHEEL ADHESION
    • B60B2310/00—Manufacturing methods
    • B60B2310/20—Shaping
    • B60B2310/226—Shaping by cutting
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60B—VEHICLE WHEELS; CASTORS; AXLES FOR WHEELS OR CASTORS; INCREASING WHEEL ADHESION
    • B60B2310/00—Manufacturing methods
    • B60B2310/20—Shaping
    • B60B2310/241—Shaping by weaving or knitting of fibers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60B—VEHICLE WHEELS; CASTORS; AXLES FOR WHEELS OR CASTORS; INCREASING WHEEL ADHESION
    • B60B2310/00—Manufacturing methods
    • B60B2310/20—Shaping
    • B60B2310/242—Shaping by laminating, e.g. fabrication of sandwich sheets
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60B—VEHICLE WHEELS; CASTORS; AXLES FOR WHEELS OR CASTORS; INCREASING WHEEL ADHESION
    • B60B2310/00—Manufacturing methods
    • B60B2310/30—Manufacturing methods joining
    • B60B2310/318—Manufacturing methods joining by adhesive bonding, e.g. glueing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60B—VEHICLE WHEELS; CASTORS; AXLES FOR WHEELS OR CASTORS; INCREASING WHEEL ADHESION
    • B60B2360/00—Materials; Physical forms thereof
    • B60B2360/30—Synthetic materials
    • B60B2360/34—Reinforced plastics
    • B60B2360/341—Reinforced plastics with fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60B—VEHICLE WHEELS; CASTORS; AXLES FOR WHEELS OR CASTORS; INCREASING WHEEL ADHESION
    • B60B2360/00—Materials; Physical forms thereof
    • B60B2360/30—Synthetic materials
    • B60B2360/34—Reinforced plastics
    • B60B2360/341—Reinforced plastics with fibres
    • B60B2360/3416—Carbone fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60B—VEHICLE WHEELS; CASTORS; AXLES FOR WHEELS OR CASTORS; INCREASING WHEEL ADHESION
    • B60B2360/00—Materials; Physical forms thereof
    • B60B2360/30—Synthetic materials
    • B60B2360/34—Reinforced plastics
    • B60B2360/344—With woven material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60B—VEHICLE WHEELS; CASTORS; AXLES FOR WHEELS OR CASTORS; INCREASING WHEEL ADHESION
    • B60B2900/00—Purpose of invention
    • B60B2900/10—Reduction of
    • B60B2900/111—Weight
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60B—VEHICLE WHEELS; CASTORS; AXLES FOR WHEELS OR CASTORS; INCREASING WHEEL ADHESION
    • B60B2900/00—Purpose of invention
    • B60B2900/10—Reduction of
    • B60B2900/112—Costs
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60B—VEHICLE WHEELS; CASTORS; AXLES FOR WHEELS OR CASTORS; INCREASING WHEEL ADHESION
    • B60B2900/00—Purpose of invention
    • B60B2900/10—Reduction of
    • B60B2900/115—Complexity
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T156/00—Adhesive bonding and miscellaneous chemical manufacture
    • Y10T156/10—Methods of surface bonding and/or assembly therefor
    • Y10T156/1052—Methods of surface bonding and/or assembly therefor with cutting, punching, tearing or severing
    • Y10T156/1062—Prior to assembly
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49481—Wheel making
    • Y10T29/49492—Land wheel
    • Y10T29/49513—Compression, e.g., nontension, spoke type wheel making
    • Y10T29/49522—Individual spoke making

Definitions

  • Composite bicycle wheels are known, but have typically been made by molding the wheel as a single piece or molding parts thereof and then mechanically assembling the molded parts to form a wheel.
  • Two piece wheels are known where each half comprises a rim, spokes and a hub, the two halves being bonded together. Wheels formed of composite portions and metal portions are also known. Wheels are known having spokes formed of composite fiber windings. In most instances the spokes of the composite wheels are of large diameter while in some cases the entire central portion of the wheel is formed as a single piece. All of the known processes for forming composite wheels are complex and costly and produce wheels which are heavier than wheels produced in accordance with the present invention.
  • all parts of the wheel are formed from carbon fiber.
  • the various pieces of the bicycle wheel comprising a rim, sidewalls, spokes, central flanges to which the spokes are attached, and a center tunnel on which the flanges are mounted, are all formed from pieces which are cut from carbon fiber cloth or tape.
  • the cut pieces are laid together and cured to form the various parts of the wheel and the parts are then bonded together in a selected order and cured to form a wheel.
  • Tension is added to the spokes by sliding the flanges mounted on the center tunnel outward and then bonding them in place. The addition of spoke tension stiffens and strengthens the wheel.
  • the described process allows for the manufacture of multiple varieties of rims and sidewalls and to join them in unique combinations to make different wheels to satisfy the needs of riders of various sizes and performance levels.
  • wheels of various degrees of stiffness, weight and durability may be made with the same tooling.
  • FIG. 1 is a perspective view of a front bicycle wheel made in accordance with the present invention
  • FIG. 2 is a side elevation view of the embodiment of FIG. 1 ;
  • FIG. 3 is an exploded view of the bicycle wheel of FIG. 1 ;
  • FIG. 4 is a perspective view of a sidewall of the bicycle wheel of FIG. 1 showing the mounting of spokes on the sidewall;
  • FIG. 5 is a section view of the sidewall of FIG. 4 showing the bonding of the spoke to the sidewall;
  • FIG. 6 is an exploded view of pieces of carbon fiber cloth being overlaid to form a sidewall
  • FIG. 7 is a cross-sectional view of the rim of a bicycle wheel made in accordance with the present invention.
  • FIG. 8 is a right side perspective view of a rear bicycle wheel made in accordance with the present invention.
  • FIG. 9 is a left side perspective view of the bicycle wheel of FIG. 8 ;
  • FIG. 10 is a right side elevation view of the bicycle wheel of FIG. 8 ;
  • FIG. 11 is a right side exploded view of the bicycle wheel of FIG. 8 ;
  • FIG. 12 is a left side exploded view of the bicycle wheel of FIG. 8 ;
  • FIG. 13 is an exploded view of the spokes of the right side of the rear bicycle wheel of FIG. 8 showing the manner in which the spokes are bonded together;
  • FIG. 14 is a section view taken along lines 14 - 14 of FIG. 10 ;
  • FIG. 15A is an enlarged view of the hub portion of the bicycle wheel of FIG. 14 showing the left side flange in its initial location;
  • FIG. 15B is an enlarged perspective view of the hub of FIG. 14 showing the left side flange moved outwardly to tension the spokes of the wheel.
  • FIG. 1 a carbon fiber front bicycle wheel 10 made in accordance with the present invention is illustrated. It will be understood that the front and rear bicycle wheels disclosed herein share the same fundamental design, a bonded structure made from simple shape carbon fiber components. However, some differences will be discussed relating to the rear wheel's need to handle the torque forces generated by pedaling.
  • bicycle wheel 10 is formed from a plurality of separate parts including a rim 12 , right and left side sidewalls 14 and 16 , spokes 18 , flanges 20 to which the inward ends of the spokes are bonded, and central tunnel 22 .
  • Each of these separate parts are formed from pieces cut from carbon fiber cloth.
  • pieces of unidirectional carbon fiber tape are also used, the choice being governed by the shape of the part and the avoidance of waste of expensive carbon fiber material.
  • spokes may be cut from unidirectional carbon fiber tape, although it will be understood that the spokes may alternatively be cut from woven carbon fiber cloth.
  • the parts may be made from a combination of cloth and unidirectional tape, the selection of appropriate materials being well within the skill of a man skilled in the art of forming carbon fiber parts and, thus, aware of the great tensile strength of carbon fiber.
  • one method of forming the sidewalls comprises joining arcuate sections of carbon fiber cloth.
  • the arcuate sections are cut from carbon fiber cloth such that a maximum number of carbon fibers run in a full end-to-end direction. Tangential to the center of each arc, these fibers form tendons that lock each arcuate section against flexing from an arcuate shape toward a rectangular shape during use. Accordingly, such placement of the carbon fibers increases the wheel's load bearing capacity.
  • each of the sections 24 overlaps the adjacent sections to provide a large bonding area 26 for the placement of epoxy or other appropriate bonding material. It has been found that overlapping each section approximately one inch creates a strong bond between the sections and also provides a strong mounting area for the spokes 18 .
  • the joined and bonded sections are cured in a conventional tool that provides mechanical compression and pressure from thermally expanding rubber and a vacuum. It has been found that forming a sidewall from two layers of sections 24 provides a strong and durable sidewall. Preferably, the second layer of sections is clocked, approximately 30 degrees, from the first section so that the overlying joints are not disposed one on top of the other to prevent overly thickened sections on the sidewall. It has also been found that the second layer of arcuate sections need not overlap as great an amount as the sections of the first layer as described above. Overlapping joints 26 provide strong mounting points for the outer ends of spokes 18 .
  • the sidewalls of the present invention are load bearing, tensioned structures. This results in a more efficient, higher performing structure by reducing peak stresses where the spokes connect to the sidewalls.
  • the sidewalls may have a dedicated braking surface with a wear indicator such as a point covering. When worn, a new braking surface may be applied.
  • rim 12 is formed from laid up pieces of woven carbon fiber cloth and unidirectional tape which, in a preferred embodiment, surround a wood core 28 .
  • Wood core 28 is not a structural element, but rather acts as a spacer since wood is of lower density than carbon fiber and thus allows the wheel to be made lighter.
  • the rim is formed by placing the laid up pieces in a steel mold and then curing them in a conventional manner under heat and pressure. The formed rims are again finished by trimming with abrasive sanders and saws.
  • the outer surface of the rim is formed in the shape of a channel 30 adapted to receive a conventional rubber tire.
  • An opening 32 ( FIG. 4 ) is provided to receive an inwardly directed air valve, through which the tire is inflated, running from the tire through the rim.
  • Flanges 20 may be formed using rectangles and disks of woven carbon fiber cloth which are assembled and bound by a wrap of unidirectional tape so that the carbon fibers are oriented such that many lie in a radial direction to support the high spoke tension connection of the present invention. Again, the laid up rectangles, disks, and tape are cured in conventional tools and then trimmed with abrasive sanders to remove rough edges.
  • Spokes 18 are preferably formed from a multilayer unidirectional sandwich of carbon fiber tape in which the fibers run lengthwise to carry high tension loads from the hub flange 20 to the sidewalls 16 . This construction increases the tensile strength of the spoke to provide improved stiffness and performance. The flatness of the spokes reduces drag to levels atypical of spoked wheels. The spokes are cured under high mechanical and expanded rubber pressure and then cut to precise shape as illustrated in the drawings. The widened ends of the spokes 18 provide a large bonding surface.
  • the first bond consists of bonding six spokes 18 to each sidewall 14 and 16 at locations 26 where the arcuate sections 24 of the sidewalls overlap.
  • the spokes 18 are mounted at the overlapping joints 26 so that they can better support the high spoke tension loads imparted to the spokes as will be described hereafter.
  • the outer ends of the spokes 18 extend through slots 34 and are bonded to the inside of the sidewall using a conventional adhesive 36 such as epoxy.
  • a conventional adhesive 36 such as epoxy.
  • both sidewalls 14 and 16 include a circumferential profile change 15 at the location of the spoke insertion slots 34 .
  • This profile change allows slots 34 to be aimed toward the opposite side flange 20 , while minimizing disruption to the sidewall surface thus improving both the strength and aerodynamics of the finished sidewall.
  • the inner ends of spokes 18 are shaped such that their bottom edges adjoin each other to define a circular opening 37 when all are mounted in place on the outer surface of the sidewall 16 .
  • flanges 20 may be formed with short spoke mounting sections 39 extending outwardly therefrom, the material between these sections having been removed to reduce weight. See FIGS. 1 and 3 .
  • Flanges 20 also include inwardly extending tubular portions 21 which are sized to receive central tunnel 22 .
  • tunnel 22 When tunnel 22 is inserted through the flanges 20 , the flanges come to rest at a first location.
  • tension is added to the spokes 18 by moving the flanges 20 laterally apart a short distance. This process results in equally tensioned spokes, eliminates the need for trimming and reduces labor time and wheel cost. This process also allows the wheel to be easily customized for different types of riders without investing in new tooling since the spoke geometry, lay up and spoke tension level can be easily changed.
  • this lateral distance need be no more than a quarter of an inch or less, with further outward movement being limited by the resistance to longitudinal extension of the longitudinally extending carbon fibers of spokes 18 .
  • a rear bicycle wheel 40 is disclosed to comprise a left-hand side as best seen in FIG. 9 which is of like configuration to the front wheel sidewall and spoke configuration discussed above with respect to FIGS. 1-7 .
  • the right side of the rear wheel employs a different form of wishbone-shaped spoke 42 (see FIG. 13 also), the inner ends 48 of which are bonded to each other and to the right side flange 44 of the rear wheel.
  • wishbone-shaped spokes 42 include a flat outer portion 46 which extends through a slot 34 in the left side sidewall 16 and is bonded to the inside of the sidewall in the manner discussed above with respect to the front wheel at FIG. 5 .
  • the inner diverging ends 48 of wishbone-shaped spokes 42 overlie each other as best seen in FIG. 13 and are bonded to define a hexagonal opening 50 .
  • the widened base of the spokes allows them to better carry shear loads resulting from the torque of the driven hub.
  • the widened end may also be formed of fiber plies oriented at an angle to the length of the spoke to further strengthen the spoke/hub connection.
  • the hub parts of the rear wheel are shown to include left side flange 52 and right side flange 44 which is shown formed to include inwardly extending tunnel 56 on which left side flange 52 is mounted as will be discussed hereafter.
  • fitting 58 mounted within the outer central opening of flange 44 are fitting 58 having a hexagonal outer surface and outwardly extending tube 60 which is adapted to receive a conventional free hub.
  • the drive side right rear spokes 42 are shaped to accommodate the high torque forces transmitted to the right side of the rear wheel 40 as a result of pedaling forces transmitted through the chain connecting the front and rear sprockets of the bicycle on which the wheels are mounted.
  • the bifurcated spokes are designed to withstand the high torque transfer forces and include large bond surfaces 46 and 48 that are oriented to best accommodate such forces.
  • the hexagonal opening 50 formed by the joining of the overlapping spokes 42 , fits over the hexagonal outer edge of fitting 58 to form a mechanical connection, thus, additionally accommodating torque transfer from the hub through the spokes to the outer wheel.
  • the spoke pattern at the inner ends 48 of the spokes where they are joined together is formed in two layers, each spoke of a single layer spanning 120 degrees such that three spokes comprise a complete circular layer.
  • the second layer of three spokes is offset 60 degrees from the first and is bonded on top of the first layer. The two-layer assembly is possible because of the flatness and width of the spokes and creates great strength in the final assembly.
  • the front and rear wheels share the same fundamental design of a bonded structure made from simple shaped flat carbon fiber components.
  • pieces of carbon fiber pre-preg woven fabric or unidirectional carbon fiber tape are cut to pattern shapes. These fabric and tape pieces are laid up in conventional tools in precise order, direction, and layers and then cured in a vacuum and under pressure at high temperature. The cured components are then trimmed to shape, and the trimmed parts are assembled, bonded together with adhesives, and then temperature cured. Finally, as discussed hereafter, high tension is introduced to the final structure.
  • FIGS. 14 , 15 A, and 15 B a sectional view of the rear wheel 40 and its central hub assembly with wheel flanges 44 and 52 mounted thereon.
  • left side flange 52 is slipped over the end of tunnel 56 which, as stated above, is formed as a part of right side flange 44 .
  • FIG. 15B shows the original position of flange 52 in phantom line, and arrow 62 illustrates the direction in which flange 52 is moved with respect to flange 44 . It will be understood that the distance of movement shown in FIG. 15B is illustrative only and, in actuality, a relatively small movement is required to add high tension to the spokes and wheel structure.
  • all spokes are lashed with high strength thread to prevent peel bond failure and increase durability and safety.
  • the lashing 45 occurs around each spoke to hub bond for the front and left rear spokes.
  • the lashing ties spokes together as they cross on their path to the sidewall. In all cases, the lashing prevents spoke to hub bond failure in case the spoke would tend to be peeled away in an accident.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Materials Engineering (AREA)
  • Composite Materials (AREA)
  • Moulding By Coating Moulds (AREA)
  • Woven Fabrics (AREA)
  • Tires In General (AREA)
US12/709,178 2009-05-26 2010-02-19 Composite fiber bicycle wheels Abandoned US20100301663A1 (en)

Priority Applications (16)

Application Number Priority Date Filing Date Title
US12/709,178 US20100301663A1 (en) 2009-05-26 2010-02-19 Composite fiber bicycle wheels
EP10781118.4A EP2435291B1 (en) 2009-05-26 2010-05-26 Composite fiber bicycle wheels
PCT/US2010/036155 WO2010138557A1 (en) 2009-05-26 2010-05-26 Composite fiber bicycle wheels
CA2800666A CA2800666A1 (en) 2009-05-26 2010-05-26 Composite fiber bicycle wheels
EP14003381.2A EP2821331A1 (en) 2009-05-26 2010-05-26 Composite fiber bicycle wheels
ES10781118.4T ES2526988T3 (es) 2009-05-26 2010-05-26 Ruedas de bicicleta de fibras compuestas
CN201080033301.4A CN102458973B (zh) 2009-05-26 2010-05-26 复合纤维自行车车轮
CN201410189841.1A CN104015552A (zh) 2009-05-26 2010-05-26 复合纤维自行车车轮
AU2010254129A AU2010254129A1 (en) 2009-05-26 2010-05-26 Composite fiber bicycle wheels
KR1020117030909A KR20120029438A (ko) 2009-05-26 2010-05-26 복합섬유 자전거 휠
JP2012513192A JP5622845B2 (ja) 2009-05-26 2010-05-26 複合ファイバー自転車ホイール
TW99135725A TW201129481A (en) 2010-02-19 2010-10-20 Composite fiber bicycle wheels
US13/738,904 US20130214586A1 (en) 2009-05-26 2013-01-10 Composite fiber bicycle wheels
JP2014192847A JP2015016863A (ja) 2009-05-26 2014-09-22 複合ファイバー自転車ホイール
HK15102132.8A HK1201498A1 (en) 2009-05-26 2015-03-03 Composite fiber bicycle wheels
US15/011,767 US9713939B2 (en) 2009-05-26 2016-02-01 Composite fiber bicycle wheels

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WO2014004727A1 (en) 2012-06-27 2014-01-03 Mad Fiber, Llc Bicycle wheel with unitary side construction
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WO2014165895A1 (en) 2013-04-11 2014-10-16 Carbon Revolution Pty Ltd Face to rim connection for a composite wheel
US8882207B2 (en) 2011-09-06 2014-11-11 Shimano Inc. Composite bicycle wheel
US20150210111A1 (en) * 2014-01-28 2015-07-30 Po-Chien Lin Carbon fiber rim and method of manufacturing the same
DE102014003824A1 (de) 2014-03-13 2015-09-17 Uwe-Holger Klose Speichen-Anordnung für ein Fahrrad-Laufrad
CN105415966A (zh) * 2015-12-22 2016-03-23 天津瑞丰源科技有限公司 可调圆度的碳纤维自行车圈
CN105437860A (zh) * 2015-12-22 2016-03-30 天津瑞丰源科技有限公司 一种耐高温碳纤维自行车轮圈
CN105539000A (zh) * 2015-12-22 2016-05-04 天津瑞丰源科技有限公司 带有夜行灯的碳纤维自行车圈
US10252568B2 (en) * 2016-03-17 2019-04-09 Campagnolo S.R.L. Bicycle wheel and relative manufacturing process
EP3632701A1 (en) * 2018-10-04 2020-04-08 Corex Materials Corporation Bicycle wheel and method of manufacturing the same
US11427028B2 (en) * 2018-10-12 2022-08-30 Corex Materials Corporation Bicycle wheel and method of manufacturing the same

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DE102016115152A1 (de) * 2016-08-16 2018-02-22 Carbofibretec Gmbh Laufrad für ein muskelbetriebenes Fahrzeug mit felgenseitig verklebten Speichen
EP3666549B1 (en) 2016-12-21 2022-04-13 Bridgestone Americas Tire Operations, LLC Nonpneumatic tire and method of assembling a nonpneumatic tire and hub
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US20160144658A1 (en) * 2009-05-26 2016-05-26 Cayucos Cowboys, Llc Composite fiber bicycle wheels
US20130214586A1 (en) * 2009-05-26 2013-08-22 Mad Fiber, Llc Composite fiber bicycle wheels
US9713939B2 (en) * 2009-05-26 2017-07-25 Cayucos Cowboys, Llc Composite fiber bicycle wheels
US20130009453A1 (en) * 2009-11-25 2013-01-10 Pierre-Jean Martin Composite wheel, in particular for a cycle, and method for manufacturing such a wheel
US9428006B2 (en) * 2009-11-25 2016-08-30 Corima Composite wheel, in particular for a cycle, and method for manufacturing such a wheel
US8882207B2 (en) 2011-09-06 2014-11-11 Shimano Inc. Composite bicycle wheel
US20130113268A1 (en) * 2011-11-09 2013-05-09 Ford Global Technologies, Llc Rim flange trim ring repair system
US20130169026A1 (en) * 2012-01-04 2013-07-04 Mu-Rong Li Bicycle rim structure
WO2014004727A1 (en) 2012-06-27 2014-01-03 Mad Fiber, Llc Bicycle wheel with unitary side construction
US9770940B2 (en) 2012-06-27 2017-09-26 Cayucos Cowboys, Llc Bicycle wheel with unitary side construction
US9108461B2 (en) * 2012-06-27 2015-08-18 Cayucos Cowboys, Llc Bicycle wheel with unitary side construction
CN104968509A (zh) * 2012-06-27 2015-10-07 卡尤科斯牛仔有限公司 具有整体式侧面构造的自行车车轮
WO2014165895A1 (en) 2013-04-11 2014-10-16 Carbon Revolution Pty Ltd Face to rim connection for a composite wheel
EP2976223A1 (en) * 2013-04-11 2016-01-27 Carbon Revolution Pty Ltd. Face to rim connection for a composite wheel
EP2976223A4 (en) * 2013-04-11 2016-11-16 Carbon Revolution Pty Ltd SURFACE HUB CONNECTION FOR A WHEEL OF A COMPOSITE MATERIAL
US9403404B2 (en) * 2014-01-28 2016-08-02 Po-Chien Lin Carbon fiber rim and method of manufacturing the same
US20150210111A1 (en) * 2014-01-28 2015-07-30 Po-Chien Lin Carbon fiber rim and method of manufacturing the same
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US20160144658A1 (en) 2016-05-26
CN104015552A (zh) 2014-09-03
WO2010138557A1 (en) 2010-12-02
CN102458973A (zh) 2012-05-16
US9713939B2 (en) 2017-07-25
EP2435291B1 (en) 2014-10-01
KR20120029438A (ko) 2012-03-26
JP2015016863A (ja) 2015-01-29
EP2435291A1 (en) 2012-04-04
EP2821331A1 (en) 2015-01-07
CA2800666A1 (en) 2010-12-02
AU2010254129A1 (en) 2012-01-19
HK1201498A1 (en) 2015-09-04
JP5622845B2 (ja) 2014-11-12
JP2012528043A (ja) 2012-11-12
EP2435291A4 (en) 2013-05-29
US20130214586A1 (en) 2013-08-22
CN102458973B (zh) 2014-06-18

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