A laced wheel manufactured from a one-piece casting, including both the hub portion and the rim portion. After casting and machining spoke interfaces, the hub and rim portions are separated and wire spokes are assembled.

A rim of a bicycle wheel having an upper bridge configured to allow mounting a tyre, a lower bridge comprising a plurality of perforated spoke-attachment seats and two opposite sidewalls connecting the upper bridge to the lower bridge. At least one of the two sidewalls has at least one recess having an axial depth that increases along a radial direction in the recess from the upper bridge towards the lower bridge.

A rim for a bicycle wheel that includes a tire, hub and spokes. The bicycle rim generally includes a radially outer tire-engaging portion, a radially inner spoke-engaging portion, a first sidewall and a second sidewall spaced apart from the first sidewall. The first and second sidewalls extend between the tire engaging and spoke-engaging portions. The tire-engaging and spoke-engaging portions and first and second sidewalls form a toroid. The rim when attached to the tire forms a side profile and a transverse cross section that positions a center of pressure of the rim.

Carbon fiber bicycle wheels are formed from parts cut from carbon fiber cloth and then joined together to form a rim, sidewalls, spokes, flanges and a center tunnel on which the flanges are mounted. The parts are then assembled, bonded together, and cured to form a wheel. During assembly, the spokes and the wheel are placed in tension by moving the flanges outwardly on the center tunnel after assembly and then bonding them in place to stiffen and strengthen the wheel. The spokes of the drive side of the rear wheel are specially shaped to accommodate torque transfer forces generated by pedaling.

A wheel with high strength flexible spokes of the present invention, including a rim and hub, and spokes between the rim and hub made of fibrous material that causes the spokes to be both lighter in weight and stronger than comparable steel spokes. The spokes are also flexible and resilient such that they can bend while retaining their integrity and strength. The wheel includes a nipple within the rim that receives the high strength spoke and allows for flexibility in adapting the spoke to wheels having differing shapes and sizes.

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.

A bicycle wheel rim including an outer annular portion adapted to receive a tire and an inner peripheral radial portion that has both a plurality of circumferentially arranged spoke openings and a braking surface on this portion.

A vehicle wheel hub assembly including an axle extending along an axial axis, a hub shell with a hub flange that is rotatable about the axle, a bearing and at least one spoke assembled and connected to the hub flange at the opening. The hub flange includes an opening to receive the spoke. The axle includes an aperture that serves to provide assembly clearance to reduce or eliminate deformation of the spoke during the assembly of the spoke with the opening.

A rim for a bicycle wheel that includes a tire, hub and spokes. The bicycle rim generally includes a radially outer tire-engaging portion, a radially inner spoke-engaging portion, a first sidewall and a second sidewall spaced apart from the first sidewall. The first and second sidewalls extend between the tire engaging and spoke-engaging portions. The tire-engaging and spoke-engaging portions and first and second sidewalls form a toroid. A maximum width of the rim is disposed closer to the spoke-engaging portion than the tire-engaging portion.

A vehicle wheel spoke connection, including: a rim; a hub; a plurality of spokes extending between the rim and hub with a first portion connected to the rim, a second portion opposed to said first portion and connected to the hub, a span portion between the rim and the hub, and an applied tensile load along the span portion; a bracing element including the rim and/or hub. The spoke has a longitudinal axis and is composed of reinforcement fibers in a matrix. The external surface of the spoke includes a pre-formed configured surface comprising a multiplicity of laterally outwardly projecting engagement surfaces that are longitudinally spaced. The spoke is connected to the bracing element by a longitudinal engagement comprising a multiplicity of longitudinally spaced overlie engagements associated with the spoke engagement surfaces. The longitudinal engagement supports the tensile load.