A method for fabricating thermoplastic bicycle spokes that securely couple to an end fitting, at one or both ends thereof, via a non-threaded, mechanical interlocking geometry. A spoke body is fabricated from thermoplastic resin, and then thermoplastic material is added, in situ (using the internal geometry of the end fitting as a form). This increases the effective diameter of the spoke at at least one end thereof to create an engagement feature that is adapted to interlock with the internal configuration of the end fitting. Additionally, by virtue of the method, the end of the spoke has a desirable fiber alignment, wherein the fibers substantially align with in-use loads.

The disclosure relates to a stable one piece wheel, which is particularly suitable for cycles having an increased system weight such as electrically powered bicycles or cargo bikes, and a method producing said vehicle wheel. Said vehicle wheel includes an annular portion, a plurality of spokes and a hub portion integrally formed by mould injection of fibre reinforced or carbo nano tubes containing thermoplastic, wherein each of the plurality of spokes comprise a substantially Z-shaped cross section with a middle leg and a pair of outer legs, wherein the angle enclosed by each of the pair of outer legs and the middle leg is greater than a right angle and wherein the length of the middle leg increases from the annular portion toward the hub portion.

A fibre applicator for applying a pre-impregnated composite fibre to a concave surface on a mold.

A composite wheel structure is made from a fiber-reinforced molding compound (FRMC) material having different resins at different axial sections of the wheel. The FRMC material can be provided as a roll of material, with different resin chemistries at different lateral sections, and applied to a wheel mold such that the different resin chemistries are provided at different axial sections. A single carrier film may have different resin chemistries at different sections, and chopped reinforcement fibers can be deposited across the width of the film. Multiple separate carrier films with different resin chemistries can be arranged side by side, and the chopped fibers added to the combined width. Reinforcing material can be provided in a prepreg and chopped and added to single carrier film at different width sections. The chopped fibers and different resins can be impregnated together to define the multi-resin FRMC material for use in the wheel layup.

The disclosure provides a wheel for an omnidirectional moving device which takes fewer man-hours for manufacturing, and a manufacturing method of the wheel for an omnidirectional moving device which takes fewer man-hours. The wheel includes an annular core body 36; a plurality of bearings 75 each including an inner ring 76 and an outer ring 77 relatively rotatable with respect to the inner ring, and the inner ring being fixed to an outer peripheral surface of the core body; and a plurality of rollers 37 each fixed to the outer ring and rotatably supported by the core body via the bearing. The inner ring is tightened and fitted to the core body.

In a resin wheel manufacturing method for forming, with a mold, a material made of a thermoplastic fiber-reinforced resin, the temperature of the mold is set to a temperature lower than a melting point of a resin matrix of the material. As the material, a billet-shaped material and a sheet-shaped material are prepared, and heated to a temperature higher than the melting point of the resin matrix. The heated billet-shaped material is held in the mold surrounded by a disc outer surface mold and a rim outer diameter mold, and the sheet-shaped material is held on a surface of the rim outer diameter mold on a punch mold side. While the sheet-shaped material is subjected to deep draw forming to form the rim portion of the wheel, the billet-shaped material is subjected to compression forming with a part of the sheet-shaped material pressed against the billet-shaped material.

Disclosed are reinforced structures. The structures are comprised of reinforced elements that have continuous fibers embedded in a matrix material. The reinforced elements are combined in a matrix material to form a desired shape of reinforced structure.

The present disclosure discloses a carbon fiber bicycle rim and a manufacturing method thereof. The carbon fiber bicycle rim comprises a ring-shaped rim body, which is integrally formed from carbon fiber. The rim body comprises an outer ring wall, an inner ring wall, and two side walls that connect the outer ring wall with the inner ring wall. The outer ring wall has an outer side that forms a semi-closed tire groove and an inner side that encloses together with the inner ring wall and the side walls to form a closed cavity. Connecting portions are arranged in the cavity. The connecting portions have one end that is connected to the outer ring wall and the other end that is connected to the side walls. The connecting portions enclose together with the outer ring wall and the side walls to form hollow channels.

A method of manufacturing a fibrous composite bicycle rim, employs a tool device having a plurality of tool components including two molding devices and one circular device. The two molding devices each have one rim flank contact surface. The circular device includes a rim well contact surface. Tool components are provided, and a first varnish coat is applied to a rim contact surface and is dried. A first fiber layer of the fibrous composite material is applied to the flank contact surface of the molding devices, forming the outer fiber layers of the pertaining rim flanks. At least one first fiber layer of the fibrous composite material is applied to the circular device which forms the rim well. The tool components of are interconnected, and the tool device is closed, is heated up, and the smooth varnish coat firmly bonds with the hardening fibrous composite material.

A method for making a bicycle rim, having a rim body with at least one integrated cavity . The cavity is enclosed by a component wall. The rim body extends in a rim plane over 360 transverse to its rotational axis.

The cavity forms a chamber in the rim body. A plurality of component walls have two lateral rim flanks, a radial inner rim base and a radial outer rim well, which limit the chamber. A rim body support structure is formed by a fibre structure. A fibre bundle is attached to a carrier layer and passed reciprocally on the carrier layer to form a basic fibre layer of the fibre structure. The fibre structure is draped in a tool mould. A filling unit is placed in the tool mould so that the filling unit keeps the volume free for the cavity and the cavity is surrounded by the component wall.