WO2004074010A2 - Jante de roue de bicyclette composite legere presentant une bonne performance de freinage - Google Patents

Jante de roue de bicyclette composite legere presentant une bonne performance de freinage Download PDF

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Publication number
WO2004074010A2
WO2004074010A2 PCT/US2004/004638 US2004004638W WO2004074010A2 WO 2004074010 A2 WO2004074010 A2 WO 2004074010A2 US 2004004638 W US2004004638 W US 2004004638W WO 2004074010 A2 WO2004074010 A2 WO 2004074010A2
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WO
WIPO (PCT)
Prior art keywords
rim
fibers
segments
walls
seams
Prior art date
Application number
PCT/US2004/004638
Other languages
English (en)
Other versions
WO2004074010A3 (fr
Inventor
James Colegrove
David Guzik
Original Assignee
Trek Bicycle Corporation
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 Trek Bicycle Corporation filed Critical Trek Bicycle Corporation
Publication of WO2004074010A2 publication Critical patent/WO2004074010A2/fr
Publication of WO2004074010A3 publication Critical patent/WO2004074010A3/fr
Priority to US11/208,706 priority Critical patent/US8002362B2/en
Priority to US12/979,606 priority patent/US20110089750A1/en

Links

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
    • B60—VEHICLES IN GENERAL
    • B60B—VEHICLE WHEELS; CASTORS; AXLES FOR WHEELS OR CASTORS; INCREASING WHEEL ADHESION
    • B60B21/00—Rims
    • B60B21/08—Rims characterised by having braking surfaces

Definitions

  • the invention is an improved one-piece, hollow bicycle wheel rim having improved sectional shape and surface for high performance caliper braking and composite layup providing lighter weight and increased strength in an economical manner.
  • Patent 6,347,839 and 6,398,313 by using general principles of optimum compaction low void composite construction specially adapted to the unique shape and structural requirements of high braking performance and light weight wheel rims using a combination of laminates incorporating fibers at different angles relative to one another.
  • the instant rims are formed from a plurality of prepreg segments, tabbed to overlap to result in a solid wall, but hollow rim.
  • the molds contain plugs or projections to form spoke nipple access holes and enabling precise alignment of the spoke hole finishing tools.
  • the valve stem hole can also be provided for in this manner.
  • the unit After forming the uncured skin, the unit is placed in a mold, the mold closed, the bladder pressurized while the mold is heated. When fully cured, the rim is removed from an opened mold and the bladder removed. Finishing of the access holes and spoke holes is accomplished and, if desired, the brake walls may be further machined.
  • the preferred carbon fiber reinforced epoxy laminate structure has a tough, high performance braking surface, which may also be made machinable.
  • Fig. 1 is a sectional view showing the sectional shape and a tire.
  • FIG. 2 is a fragmentary side elevational view of a portion of the rim.
  • FIG. 3 is a side elevational view of the rim.
  • FIG. 4 is a fragmentary bottom plan view of a portion of the rim.
  • Fig. 5 is a schematic view showing prior art fiber alignment.
  • Fig. 6 is a schematic view showing fiber alignment in the invention.
  • a wheel rim 10 is formed of fiber reinforced plastic resin.
  • this is formed predominantly of a high modulus fiber, such as carbon fiber, in an epoxy matrix, with special structural locations containing other fibers commensurate with needs in areas having unique performance and/or manufacturing requirements, such as brake surfaces.
  • a high modulus fiber such as carbon fiber
  • epoxy matrix with special structural locations containing other fibers commensurate with needs in areas having unique performance and/or manufacturing requirements, such as brake surfaces.
  • strong, but more easily machinable fibers, such as glass can be used in certain areas, and tougher fibers, such as Kevlar, can be used in high impact areas.
  • the fibers in the individual segments are aligned in laminations such as taught in U.S. Patents Nos. 5,624,519 and 6,270,104 sharing a common assignee with this application.
  • the high strength and high modulus properties of carbon fiber can be used to advantage to produce a shape of complex curvature having substantially uniform strength in the needed directions in the finished structure, while the optimum compaction and low void methods, as improved for wheel rims as taught herein, produces the finished structure having a substantially uniform density.
  • Rim 10 as shown as a high performance road racing rim adapted to receive a conventional glued-on "tubular” or “sew-up” tire 11 in which the tire and tube are formed together as a unit and this unit is adhesively affixed to the tire well 12 and further mechanically held in place by virtue of the inflation pressure in the tube, compressing the unit around the rim 10.
  • tire well 12 extends between left and right apexes 14, 16.
  • Bevels 18, 20 are bevels 18, 20. Bevels
  • Well 12 is smoothly curved with a dimension corresponding to that needed to receive a high performance "sew-up" tire 11 with a diameter of around one inch, typically 21 to 28 mm.
  • bevels 18, 20 form a significant spacing between apexes 14, 16 and brake surfaces 22, 24. Because bevels 18, 20 shown in section in Fig. 1 are formed in a three dimensional, circular rim, the form, in actuality, a conical segment at an angle from the central axis (corresponding to the axis of the axle of the wheel) of about 20 degrees from the horizontal.
  • braking surfaces 22, 24 which join left and right inwardly angled interior walls 26, 28.
  • Inwardly angled interior walls 26, 28 join walls 22, 24 at concavities 30, 32.
  • Concavities 30, 32 provide lateral spacing of brake walls 22, 24 away from the center plane of the wheel, inwardly angled interior walls 26, 28 meet spoke bed 34.
  • Braking surfaces 22, 24 are substantially flat and preferably 19 to 22 mm across for a high performance road tire of a nominal width of about the same nominal width. This width is considered a high performance, light weight, high speed tire having minimal weight and friction.
  • wider rims could be designed for wider tires, such as 24 or 25 mm rims for tires of those nominal dimensions for wheel specially designed for rough road races, such as races historically run on cobblestones, or races in weather conditions requiring wider tires.
  • This rim is made from a one piece mold, having no joints. As such, it is different from several alternative rims, such as those using a pair of mating arc segments, or a pair of arc segments joined with special joint pieces. Unlike other one piece wheels ⁇ such as disc wheels — using all fiber reinforced plastic rim, spokes and hub assemblies, the instant rim uses separate components of rim, spoke and hub assembly to obtain maximum lightness and performance
  • the preforms used to make the one piece rim disclosed herein differ from other attempts to form wheels from fiber reinforce plastics in that other methods typically attempt to maximize the size and continuity of the preforms by using the largest preforms suitable to molding.
  • preferably six segmented preforms per side are used. The use of segmented preforms enables the alignment of fibers that more closely follow the lines of stress in the structure.
  • an individual fiber line 104 is tangent at a first point 106 on the rim.
  • a parallel fiber line 110 is skewed at 45 degrees from the tangent at a second point, 108, spaced 45 degrees circumferentially from the first point 106.
  • fiber lines 104, 108 angularly diverge from the tangent. Because carbon fiber is extremely strong at certain load orientations, it is desirable to keep the fiber orientation in line with the loads - mainly circumferentially and radially.
  • Each side of the rim is layed up of six segments, each abutting or with a slight over lap at seams 220, 222, 224, 226, 228, 230.
  • the reverse side is layed up in a similar fashion.
  • the segments from side to side are staggered, as shown in Fig. 4, so that a seam, such as 220, will be aligned with the center of the reverse side segment 200R, and the seams between reverse side segments will be aligned opposite the center of a segment, such as 200.
  • a seamless rim will be formed.
  • the tirewell preform consists of 5-6 segments with circumferentially overlapping tabs to form a seamless overlapping continuous surface.
  • the tirewell preforms also overlap to structurally tie the two braking sidewalls together forming one continuous structure. Reinforcing the apexes and spoke bed with continuous unidirectional carbon fiber bundles or ropes also contributes to strength. In this manner, strength, stiffness and mass are balanced rather than concentrated at certain points.
  • the overlapping ends of the tire well preforms provide junctions between adjacent fiber orientations, with more fibers at the junction.
  • the compression of the molding process coupled with effective curing of the plastic resin results in a solid structure, even with the junctions, seams and overlaps.
  • the rim of this invention relies primarily on an inner layer of high modulus fiber reinforcement in a thermoset plastic matrix. Excellent structural performance is obtained with carbon fiber in an epoxy matrix, although other combinations are not intended to be excluded.
  • the structural and mechanical characteristics of carbon fiber bear significantly on the mechanical properties of the braking surface, should the braking surface be comprised of the same fiber reinforced plastic as the structural layer.
  • the high modulus, extremely hard and stiff carbon has a low coefficient of friction when exposed to elastomeric caliper brake pads such as those used on bicycles.
  • the carbon comprises about 60 to 70 percent or more of the structure, (preferably 65/35 carbon to resin by weight) brake surfaces have been an inherent problem for carbon fiber bicycle wheel rims.
  • the entire exterior surface of the wheel is a separate lamination formed of a glass fiber scrim in an epoxy matrix.
  • the glass provides some structural strength, but it is negligible when compared to the carbon fiber structural base laminations. The major structural effect is mainly to maintain the outer layer intact.
  • the glass fiber scrim provides a superior braking surface. Because the outer layer and the inner base laminations are fibers in an epoxy resin matrix applied one over another prior to compression and curing, in the curing process, the epoxy forms a continuous matrix of chemically cross linked molecules.
  • the outer, glass reinforced layer has the additional advantage of being easily machinable, as compared to a layer of carbon fiber reinforcing fibers. Carbon fiber machining causes substantial wear on tools.
  • the completed wheel can be formed having complementary components with the traits of the rim.
  • more spokes can be used. Mass in the rim can be reduced, with load being borne by spokes. Reduced mass helps the rider to devote power to greater speed on uphill climbs, while aerodynamic drag is not a substantial factor in speed riding downhill, and in fact distributing load over more spokes may assist in reducing wheel 'shimmy. 1
  • an all carbon wheel with integral hub spokes and rims may have only three large spokes, at a weight penalty.
  • a high performance aerodynamic carbon rim wheel with separate hub, spokes and carbon fiber rim may have sixteen spokes.
  • the instant rim can be advantageously built into a wheel having twenty front spokes and twenty four rear spokes.
  • An offset spoke bed as taught in Patent No. 6,679,561 could be used.
  • a standard sporting goods grade epoxy can be used for the prepreg materials from which the various layers are formed into prepregs. Because of the demands on the rims caused by braking, it has been discovered that a high temperature epoxy performs better. This insures that the structural integrity of the rim is maintained even on long downhill rides with extensive braking resulting frictionally created heat.
  • Bicycle wheel rims formed of a hollow section have typically been machined, such as by drilling, to provide access holes for spoke attachment.
  • Spoke attachment typically involves lacing wire (or other elongate structure) spokes from hub to rim, and fastening a spoke nipple to the end of the spoke, threaded thereto, for tightening and adjustment or 'truing.
  • Point loads on the rim at the location of the nipple are substantial, so the load can typically be spread by use of a washer or eyelet.
  • the size of the washer is limited by the size of the access hole, as is the ease of manipulation of the nipple, or, when automatically assembled, the size of the tools used for automatic wheel assembly.
  • Drilling access holes in a hollow carbon fiber reinforced plastic rim is a difficult operation given the size of the holes and the strength, stiffness and hardness of the carbon. Some breakage of the fibers at the edge of the hole also results in abrupt changes in strength and stress paths in the material. Further, these edges provide manipulation difficulty for the wheel assembler.
  • the molding and preform arrangement used utilizes molded access apertures. This could be and preferably will be expanded to include the valve hole and spoke holes. By forming these in the mold, superior manufacturing efficiency, tool utilization, ease of manipulation and assembly and improved structural integrity over drilled holes is gained.
  • the spoke bed 34 formed herein uses the strength properties of carbon fiber reinforced plastic, and the design utility in molding to have a spoke bed thinner than in other carbon fiber rims. Although thinner, the spoke bed is formed with sufficient width to enable spoke drilling at a 2.75 degree drill angle.
  • the spoke holes, aligned with the aforementioned access apertures can also be formed with 0.100" stagger. This will provide greater lateral stability in the wheel, with the designed number of spokes, such that a lower wheel weight, particularly at the rim, will permit good high speed, downhill performance.
  • a bladder is used to mold this one piece, monocoque rim consistent with the teachings of Patent Nos. 5,624,519 and 6,270,104 and could be as simple as an inner tube or as complex as a specially formed conforming bladder.
  • Rim 10 is formed of an inner lamination 300 and an outer lamination 320.
  • Lamination 320 overlies the entire rim, including tire well 12, apexes 14, 16 and extend under braking surfaces 22, 24 to walls 26, 28 and spoke bed 34. This will extend to a second bladder used in conjunction with the trapped rubber thermally expandable flexible insert which is used to form the tire well and hook bead shape in the clincher style rim. All bladders and insert are removable.
  • Braking surface laminations particularly advantageously use glass fibers having properties much different from high strength, high modulus carbon in the inner lamination 300.
  • Braking surfaces 22, 24 perform best when used in conjunction with the highly developed bicycle caliper brakes, when surfaces 22, 24 are either formed in a precise mold or machined to a high level of smoothness and trueness.
  • the carbon itself provides a less desirably hard surface and generally does not perform optimally in demanding conditions such as long, fast mountain road downhill rides.
  • Brake surfaces 22, 24 are also subject to wear and damage when in use, particularly as a result of contamination by foreign objects such as sand, stones, road tar and the like.
  • the glass scrim has a more optimum coefficient of friction with typical elastomeric caliper brake shoes, thus the combination of materials provides a performance advantage.
  • Glass reinforced plastic has improved thermal, frictional, and machinability properties

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Materials Engineering (AREA)
  • Moulding By Coating Moulds (AREA)
  • Laminated Bodies (AREA)

Abstract

La présente invention concerne une jante de roue de bicyclette en plastique renforcé par des fibres. Cette jante est constituée de six segments par côté et elle est formée dans une section présentant des surfaces de freinage pouvant être usinées et précisément formées et combinant, de préférence, une stratification interne du plastique renforcé par des fibres à haut module et une stratification externe constituée de matériaux à coefficient de frottement amélioré sur les surfaces de freinage.
PCT/US2004/004638 2003-02-14 2004-02-17 Jante de roue de bicyclette composite legere presentant une bonne performance de freinage WO2004074010A2 (fr)

Priority Applications (2)

Application Number Priority Date Filing Date Title
US11/208,706 US8002362B2 (en) 2004-02-17 2005-08-15 Optimal thermal properties in light weight and high performance braking composite clincher or tubular tire bicycle wheel rim
US12/979,606 US20110089750A1 (en) 2004-02-17 2010-12-28 Optimal thermal properties in light weight and high performance braking composite clincher or tubular tire bicycle wheel rim

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US44764203P 2003-02-14 2003-02-14
US60/447,642 2003-02-14

Related Parent Applications (1)

Application Number Title Priority Date Filing Date
PCT/US2004/004970 Continuation-In-Part WO2004074081A2 (fr) 2003-02-14 2004-02-17 Jante de roue de bicyclette a pneu a talon ou pneu tubulaire composite leger et a freinage de haute performance

Related Child Applications (2)

Application Number Title Priority Date Filing Date
PCT/US2004/004970 Continuation-In-Part WO2004074081A2 (fr) 2003-02-14 2004-02-17 Jante de roue de bicyclette a pneu a talon ou pneu tubulaire composite leger et a freinage de haute performance
US11/208,706 Continuation-In-Part US8002362B2 (en) 2004-02-17 2005-08-15 Optimal thermal properties in light weight and high performance braking composite clincher or tubular tire bicycle wheel rim

Publications (2)

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WO2004074010A2 true WO2004074010A2 (fr) 2004-09-02
WO2004074010A3 WO2004074010A3 (fr) 2004-11-25

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Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP1997647A1 (fr) * 2007-05-30 2008-12-03 CAMPAGNOLO S.r.l. Jante pour roue de bicyclette fabriquée à partir d'un matériau composite avec un indicateur d'usure et roue comportant une telle jante
EP2412543A1 (fr) * 2010-07-27 2012-02-01 Shimano Inc. Jante de bicyclette
WO2022246160A1 (fr) * 2021-05-20 2022-11-24 Guerrilla Industries LLC Structures annulaires formées de matériaux composites et systèmes et procédés de formation de structures annulaires à partir de matériaux composites
US11572124B2 (en) 2021-03-09 2023-02-07 Guerrilla Industries LLC Composite structures and methods of forming composite structures
US11745443B2 (en) 2017-03-16 2023-09-05 Guerrilla Industries LLC Composite structures and methods of forming composite structures

Citations (12)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4030754A (en) * 1976-01-21 1977-06-21 Hercules Incorporated Composite lightweight wheel rim
US4294490A (en) * 1980-02-06 1981-10-13 Motor Wheel Corporation Fiber-reinforced composite wheel construction
US5080444A (en) * 1988-10-12 1992-01-14 E. I. Du Pont De Nemours And Company Vehicle wheel
US5249846A (en) * 1991-02-04 1993-10-05 Martin Pierre A Wheel rim made of composite materials for cycles and the like
US5564793A (en) * 1993-05-20 1996-10-15 Whiteford; Michael B. Wheel and method of forming same
US5734142A (en) * 1996-07-19 1998-03-31 Trek Bicycle Corporation Method of welding electrically conductive metal profiles
US5985072A (en) * 1996-11-15 1999-11-16 Compagnie Generale Des Etablissements Michelin - Michelin & Cie Method and device for the manufacture of a rim preform
US6086161A (en) * 1997-06-18 2000-07-11 Nimble Bicycle Company High performance broad application wheel
US6216758B1 (en) * 1999-04-12 2001-04-17 Alex Machine Industrial Co., Ltd. Bicycle wheel rim with resilient wear-resisting rings to minimize wearing of a tire
US6347839B1 (en) * 2000-09-25 2002-02-19 Polymeric Corporation The Composite rim
US6398313B1 (en) * 2000-04-12 2002-06-04 The Polymeric Corporation Two component composite bicycle rim
US20040021366A1 (en) * 2002-07-31 2004-02-05 James Colegrove Optimum compaction low void composite bicycle wheel rim

Patent Citations (12)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4030754A (en) * 1976-01-21 1977-06-21 Hercules Incorporated Composite lightweight wheel rim
US4294490A (en) * 1980-02-06 1981-10-13 Motor Wheel Corporation Fiber-reinforced composite wheel construction
US5080444A (en) * 1988-10-12 1992-01-14 E. I. Du Pont De Nemours And Company Vehicle wheel
US5249846A (en) * 1991-02-04 1993-10-05 Martin Pierre A Wheel rim made of composite materials for cycles and the like
US5564793A (en) * 1993-05-20 1996-10-15 Whiteford; Michael B. Wheel and method of forming same
US5734142A (en) * 1996-07-19 1998-03-31 Trek Bicycle Corporation Method of welding electrically conductive metal profiles
US5985072A (en) * 1996-11-15 1999-11-16 Compagnie Generale Des Etablissements Michelin - Michelin & Cie Method and device for the manufacture of a rim preform
US6086161A (en) * 1997-06-18 2000-07-11 Nimble Bicycle Company High performance broad application wheel
US6216758B1 (en) * 1999-04-12 2001-04-17 Alex Machine Industrial Co., Ltd. Bicycle wheel rim with resilient wear-resisting rings to minimize wearing of a tire
US6398313B1 (en) * 2000-04-12 2002-06-04 The Polymeric Corporation Two component composite bicycle rim
US6347839B1 (en) * 2000-09-25 2002-02-19 Polymeric Corporation The Composite rim
US20040021366A1 (en) * 2002-07-31 2004-02-05 James Colegrove Optimum compaction low void composite bicycle wheel rim

Cited By (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP1997647A1 (fr) * 2007-05-30 2008-12-03 CAMPAGNOLO S.r.l. Jante pour roue de bicyclette fabriquée à partir d'un matériau composite avec un indicateur d'usure et roue comportant une telle jante
US7918514B2 (en) 2007-05-30 2011-04-05 Campagnolo, S.R.L. Rim for a bicycle wheel made from composite material with a wear indicator and wheel comprising such a rim
EP2412543A1 (fr) * 2010-07-27 2012-02-01 Shimano Inc. Jante de bicyclette
CN102343766A (zh) * 2010-07-27 2012-02-08 株式会社岛野 自行车的轮圈
CN102343766B (zh) * 2010-07-27 2014-07-02 株式会社岛野 自行车的轮圈
US8905491B2 (en) 2010-07-27 2014-12-09 Shimano Inc. Bicycle rim
US11745443B2 (en) 2017-03-16 2023-09-05 Guerrilla Industries LLC Composite structures and methods of forming composite structures
US11572124B2 (en) 2021-03-09 2023-02-07 Guerrilla Industries LLC Composite structures and methods of forming composite structures
WO2022246160A1 (fr) * 2021-05-20 2022-11-24 Guerrilla Industries LLC Structures annulaires formées de matériaux composites et systèmes et procédés de formation de structures annulaires à partir de matériaux composites

Also Published As

Publication number Publication date
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