WHEEL COMPONENT FOR A BICYCLE

Abstract

A wheel component for bicycles with a straight spoke, with a center portion and two end portions, to detachably connect a hub with a rim. The spoke is supported on a hub and a rim by the end portions. The spoke is manufactured from a fibrous composite material and includes a matrix material and embedded reinforcing elements. The spoke is formed without loops and eyelets. The end portions are integral with the center portion, forming an end of the spoke each. At least one of the two end portions includes a threaded portion. At least some of the reinforcing elements are configured as long fibers extending through the entire center portion and over at least a substantial part of the two end portions each. At least one end portion includes a cross-sectional region with embedded reinforcing long fibers, and at least one cross-sectional portion without reinforcing embedded long fibers.

Claims

1. A wheel component for a vehicle, with a spoke configured straight with a center portion and two end portions, to detachably connect the spoke with a hub and with a rim by means of the end portions, wherein at least one of the two end portions comprises a threaded portion, wherein the spoke is manufactured from a fibrous composite material and comprises at least one matrix material and reinforcing elements embedded therein, wherein the spoke is formed without loops and eyelets; the end portions are configured integrally with the center portion, each forming an end of the spoke; the threaded portion is formed in one piece with the end portion; and at least some of the reinforcing elements are configured as long fibers, and extend through the entire center portion, and over at least a substantial part of the two end portions; and at least one end portion comprises a cross-sectional region with long fibers embedded therein as reinforcing elements, and at least one cross-sectional portion without long fibers embedded therein as reinforcing elements.

2. The wheel component according to claim 1, wherein at least one end portion has an outer diameter that is larger than at least one transverse dimension in the center portion and wherein at least one of the end portions comprises a threaded portion which screws to a spoke nipple.

3. The wheel component according to claim 1, wherein at least one end portion has a conical portion adjacent to the center portion and a support portion adjacent thereto.

4. The wheel component according to claim 1, wherein at least one of the end portions comprises a head portion for supporting the spoke.

5. The wheel component according to claim 1, wherein in the cross-sectional portion shorter reinforcing elements are embedded.

6. The wheel component according to claim 1, wherein a considerable part of the cross-sectional region comprises solely long fibers and wherein a considerable part of the cross-sectional portion comprises solely shorter reinforcing elements.

7. The wheel component according to claim 1, wherein a considerable part of the cross-sectional region comprises solely long fibers and wherein a considerable part of the cross-sectional portion does not comprise reinforcing elements.

8. The wheel component according to claim 1, wherein the cross-sectional portion forms a significant share of the cross-sectional area of the spoke in the head portion.

9. The wheel component according to claim 1, wherein at least part of the shorter reinforcing elements is formed by fiber bits or reinforcing particles.

10. The wheel component according to claim 1, wherein the matrix material of the spoke is uniform overall and wherein the spoke is in one piece.

11. The wheel component according to claim 1, wherein the cross-sectional region has a cross section deviating from a rotationally symmetrical cross section in at least one end portion and wherein the deviating cross section is taken from a group of shapes comprising a polygonal, star-shaped, oval, elliptic or conical shape.

12. The wheel component according to claim 1, wherein the cross-sectional portion is centrally accommodated in the end portion and has a cone-like portion.

13. The wheel component according to claim 1, wherein the cross-sectional portion radially surrounds the cross-sectional region, and wherein the cross-sectional portion forms a thickening on the end portion.

14. The wheel component according to claim 1, wherein the cross-sectional region comprises a thermoplastic matrix material and wherein the spoke body comprises a thermoplastic matrix material.

15. The wheel component according to claim 1, comprising a rim and a hub and several separate spokes configured straight, wherein the hub is connected detachably with the rim by means of the spokes and wherein the spokes are supported on the end portions of the spokes.

16. The wheel component according to claim 15, wherein the center portion is aerodynamic in shape.

17. The wheel component according to claim 15, wherein the end portion of the spoke is accommodated at least nearly completely within the rim.

18. The wheel component according to claim 15, wherein the material of the rim comprises a fibrous composite material and/or metal.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0048] The figures show in:

[0049] FIG. 1 a schematic illustration of a racing bicycle;

[0050] FIG. 2 a schematic illustration of a mountain bike;

[0051] FIGS. 3-7 schematic sectional views of spokes;

[0052] FIGS. 8-10 side views and a perspective view of a spoke; and

[0053] FIGS. 11-13 schematic views of a spoke nipple.

DETAILED DESCRIPTION

[0054] FIGS. 1 and 2 show a mountain bike and a gravel bicycle or racing bicycle 100 respectively, which are each equipped with wheel components 1 according to the invention. The mountain bike or racing bicycle 100 is provided with a front wheel 101 and a rear wheel 102.

[0055] The two wheels 101, 102 are provided with spokes 10. A sprocket device 111 is provided. Basically, conventional caliper brakes or other brakes, for example disk brakes may be provided.

[0056] The bicycles 100 are each provided with a frame 103, a handlebar 106, a saddle 107, a fork or suspension fork 104 respectively, and in the case of the mountain bike or a racing bicycle or gravel bicycle (gravel bike), a rear wheel damper 105 may be provided. A pedal crank 112 with pedals serves for driving. Optionally the pedal crank 112 and/or the wheels may be provided with an electric auxiliary drive. The hubs of the wheels may be attached to the frame by means of a clamping mechanism such as a through axle or a quick release.

[0057] The FIGS. 1 and 2 show the wheel component 1 according to the application with spokes 10 and spoke nipples 50. The spokes connect the hub 108 with the rim 109. The spoke nipples 50 shown are accommodated in the interior of the hollow rim 109, so as to be not visible in the side view.

[0058] FIGS. 3 to 10 illustrate different wheel components 1 according to the application, configured as spokes 10. FIG. 3 illustrates a cross section of a spoke 10, comprising an elongated center portion 11 and two end portions 20, 30. The spoke 10 is configured integrally overall, and the spoke body 15 has no parting surfaces between the end portions 20, 30 and the center portion 11.

[0059] The spoke 10 consists of a fibrous composite material 2 and comprises a matrix material 3 and reinforcing elements 4. Long fibers 5 extend (at least nearly) completely over the length 10a of the spoke 10 centrally through the end portion 30, the center portion 11 and the end portion 20 at the other end of the spoke 10. At the very end, the long fibers 5 may be covered, so as to be invisible from the outside.

[0060] Reference is made to the fact that the FIGS. 3-10 depict the wheel component 1 with the spoke 10 not true to scale, so as to more clearly show every part and component of the spoke 10. In reality, the spoke 10 has a length 10a of for example 290 mm or 300 mm and, in a non-aerodynamic configuration, it may for example have a diameter between 1 mm and 3 mm or 4 mm. Other dimensions are likewise possible. These dimensions are also indicated so as to illustrate that the figures are not shown true to scale.

[0061] FIG. 3 shows that the end portion 30 has a threaded portion 31 configured as an external thread and extending across the entire width respectively length 30a of the end portion 30. The other end portion 20 has a conical portion 23 adjacent to the center portion 11, and a supporting or cylindrical portion 24 succeeding the conical portion 23 and reaching up to the spoke end.

[0062] In simple configurations, the center portion 11 is configured round, so that the minimum transverse dimension 12, the medium transverse dimension 13, and the maximum transverse dimension 14 each show the same value, and presently correspond to the diameter of the center portion 11. In other configurations, the spoke 11 may be configured e.g. aerodynamically, so that the minimum, medium, and maximum transverse dimensions 12-14 are different from one another.

[0063] The long fibers 5 extend over the entire length of the spoke 10 as reinforcing elements 4. The long fibers 5 in the end portions 20, 30 are located only in the (central) cross-sectional region 25 at the end portion 20 and the central cross-sectional region 35 at the end portions 30.

[0064] The cross-sectional portion 36, which likewise consists of a fibrous composite material 2 and has the same matrix material 3 as the center portion 11, follows the cross-sectional region 35 radially outwardly at the end portions 30.

[0065] Unlike the center portion 11 and the cross-sectional regions 25, 35, shorter reinforcing elements are employed in the cross-sectional portions 26, 36, which may consist of short fibers 6a or fiber bits 6b and/or reinforcing particles 6c. In the cross-sectional portions 26, 36 no reinforcing elements at all or only smaller/shorter reinforcing elements may be present.

[0066] In simple configurations, short fibers 6a are injection molded to the ends 16, 17, together with a matrix material 3, wherein, at least in this place, the matrix material 23 is first re-plasticated, if it had already (somewhat) solidified. This manufacturing process prevents the forming of separate boundary surfaces or adhesion surfaces or surfaces between the cross-sectional portion 36 and the cross-sectional region 35, inside of the matrix material 3. A transition between the cross-sectional region 35 and for example the cross-sectional portion 36 is adjustable only by modifying the embedded reinforcing material. This results in a particularly high stability under load of the wheel component 1 according to the application.

[0067] In the exemplary embodiment according to FIG. 3, the long fibers 5 are located in the central regions 29, 39 of the end portions.

[0068] FIG. 4 illustrates a slightly different exemplary embodiment of a wheel component 1 according to the application with a spoke 10, wherein only the end portion 20 and a part of the center portion 11 are depicted.

[0069] Unlike FIG. 3, the end portion 20 is configured conical overall. Again, the cross-sectional region 25 is interspersed with long fibers 5, while the cross-sectional portion 26 follows radially outwardly, having the same matrix material 3 but shorter reinforcing elements 6. Again, the end portion 20 forms the head portion 21 of the spoke 10, and serves to support the spoke on the rim or the hub.

[0070] As the schematic sketch on the right in FIG. 4 shows, both the center portion 11 and the end portion 20 are configured rotationally symmetrical in the exemplary embodiment according to FIG. 4. Again, it is possible for the center portion 11 to be configured aerodynamically, so that the cross sectional shape deviates from a circular shape.

[0071] FIG. 5 shows another variant of a spoke 10 as the wheel component 1, wherein the end portion 20 has no conical portion 23, but only an orthogonally protruding supporting or cylindrical portion 24.

[0072] On the right in FIG. 5, some examples of different reinforcing elements 6a, 6b and 6c are shown, which can be employed in the cross-sectional portion 26 at the end portion 20 (and in the cross-sectional portion 36 of the other end portion 30).

[0073] Both randomly placed shorter reinforcing elements 6a and unidirectional reinforcing elements 6a in short shapes, and fiber bits 6b in the same or different orientations, and reinforcing particles 6c, may be employed. A combination of different reinforcing elements 6a, 6b and 6c is likewise possible.

[0074] FIG. 5 shows only one end portion 20. The other end portion 30 may be configured identically. Alternately, both of the end portions 20, 30 (also) have a threaded portion 31. The shape of one or both of the end portions may be configured as illustrated in FIG. 3, 4 or 5. A wheel may comprise different spokes.

[0075] FIG. 6 shows a variant of a wheel component with a spoke 10, wherein, following the pultrusion, the end 16 is melted onto the end portion 20, and a cone-like element is inserted, wherein after removal, the cavity leaves a cone-like portion 28, which is filled up with a fibrous composite material 2 and a matrix material 3 and reinforcing elements 4. Centrally, the cross-sectional portion 26 with shorter reinforcing elements 6 is provided, while the long fibers 5 extend annularly around the cross-sectional portion 26 in the cross-sectional region 25. Overall, the end portion is widened to a diameter 22.

[0076] FIG. 7 shows another variant, wherein the end portion 30 is configured longer, respectively wherein the threaded portion 31 does not extend over the entire length of the end portion 30. An end portion 37 follows, configured cylindrically.

[0077] In FIG. 7, the long fibers 5 are again provided over the entire length of the spoke 10, virtually extending over the entire length of the end portions 20, 30 and the center portion 11.

[0078] FIG. 7 shows on the right a cross section in the end portion 37. One can clearly see that the reinforcing elements 4 disposed in a circle in the center portion 11, take a different cross sectional shape in the end portion 30 (and optionally, also in the end portion 20). Namely, the cross sectional shape is configured non-round, so as to form a deviating cross section 37a, similar to a rectangle, showing inwardly extending bulgings in the side surfaces. The envelope curve 33 drawn in a broken line surrounds the reinforcing elements 4 the closest possible, and it is shown only for illustrating the shape. In reality, this envelope curve does not exist. It is not a separate layer. The spoke body is manufactured of one single material and is one-piece (monobloc). The cross sectional shape may also be referred to as star-shaped. This enables transmission of a higher rotational force, which is an advantage when setting the spoke tension.

[0079] Other deviating cross sectional shapes are also possible for the cross-sectional region respectively long fiber region 35, thus, its cross sectional shape may be triangular or oval or T-shaped or V-, or W-shaped or the like.

[0080] FIGS. 8-10 illustrate another wheel component with a spoke 10, FIGS. 8 and 9 showing two side views, clearly showing that the spoke 10 is configured aerodynamically, so that the minimum transverse dimension 12 is considerably smaller than the maximum transverse dimension 14 in the center portion 11.

[0081] An the ends 16, 17, the spoke 10 is once again configured round on the end portions 20, 30, and is provided with a threaded portion 31 at the end portion 30. The outer diameter 32 on the end portion 30 may correspond to the maximum transverse dimension 14 in the center portion 11.

[0082] FIGS. 11, 12 and 13 illustrate a wheel component 1 according to the application with a spoke nipple 50. FIGS. 11 and 12 show two slightly different exemplary embodiments, each in cross section.

[0083] The spoke nipples 50 consist of a fibrous composite material 2 with a matrix material 3 and reinforcing elements 4. The reinforcing elements 4 may be configured as long fibers 5 or as shorter reinforcing elements 6.

[0084] The spoke nipple 50 is provided with a nipple body 55 extending over a length 55a, which may for example be 10 mm. Somewhat shorter and somewhat longer configurations are likewise possible. The nipple body 55 has a length 55a greater than the diameter 61 of the nipple body.

[0085] The nipple body is provided with end portions 51 and 52 on the ends 58 and 59. The nipple head 53 is configured rounded at the end 58, providing the contact surface, on which the nipple is for example supported on the rim.

[0086] The nipple head 53 is provided with a takeup 54 for the threaded end of a spoke. The takeup is configured with an internal thread 56. The nipple head 53 screws onto a spoke end by way of the thread 56. The takeup 54 may be configured as a through hole. It is also possible for the other end 51 to be partially or completely closed. Then, the takeup 54 is a blind hole.

[0087] FIG. 13 shows a top view of the end portion 51 of the spoke nipple 50. Thus, the tool receiving socket 60 with the wrench size 62 can be seen on the nipple body 55. In the center, the takeup 54 can be seen, in which the thread 56 is configured.

[0088] Employing spoke nipples 50 of a fibrous composite material provides a lighter-weight spoke nipple, which furthermore also reliably prevents possible contact corrosion between different metals. In particular, when employing reinforcing elements with a glass fiber content, these problems are reliably prevented.

[0089] All the configurations achieve a connection with an adhesive bond and of one single material (monobloc). A single and integral piece is provided.

[0090] In manufacturing spoke nipples 50, for example 20, 30, 40 or more cavities in a manufacturing mold can be filled concurrently, so that after manufacturing a mold, inexpensive manufacture is possible.

[0091] The thread in the wheel components is provided directly in the fibrous composite material.

[0092] While particular embodiments of the present wheel component for a bicycle have been described herein, it will be appreciated by those skilled in the art that changes and modifications may be made thereto without departing from the invention in its broader aspects and as set forth in the following claims.

LIST OF REFERENCE NUMERALS

[0093] 1 wheel component [0094] 2 fibrous composite material [0095] 3 matrix material [0096] 4 reinforcing elements [0097] 5 long fiber [0098] 6 shorter reinforcing elements [0099] 6a short fibers [0100] 6b fiber bits [0101] 6c reinforcing particles [0102] 7 longitudinal axis [0103] 10 spoke [0104] 10a length of 10 [0105] 11 center portion [0106] 11a length of 11 [0107] 12 transverse dimension (minimum) [0108] 13 transverse dimension (medium) [0109] 14 transverse dimension (maximum) [0110] 15 spoke body [0111] 16 end [0112] 17 end [0113] 19 central region [0114] 20 end portion [0115] 20a length of 20 [0116] 21 head portion [0117] 22 outer diameter [0118] 23 conical portion [0119] 24 supporting, cylindrical portion [0120] 25 cross-sectional region [0121] 26 cross-sectional portion [0122] 28 cone-like portion [0123] 29 central region [0124] 30 end portion [0125] 30a length of 30 [0126] 31 threaded portion [0127] 32 outer diameter [0128] 33 envelope curve [0129] 35 cross-sectional region, long fiber region [0130] 36 cross-sectional portion, short fiber portion [0131] 37 end portion [0132] 37a deviating cross section [0133] 38 cone-like portion [0134] 39 central region [0135] 50 spoke nipple [0136] 51 end portion [0137] 52 end portion [0138] 53 nipple head [0139] 54 takeup [0140] 55 nipple body [0141] 55a length [0142] 56 thread [0143] 58 end (rounded) [0144] 59 end (tool end) [0145] 60 tool receiving socket [0146] 61 diameter [0147] 62 wrench size [0148] 100 bicycle [0149] 101 wheel, front wheel [0150] 102 wheel, rear wheel [0151] 103 frame [0152] 104 fork, suspension fork [0153] 105 rear wheel damper [0154] 106 handlebar, handle [0155] 107 saddle [0156] 108 hub [0157] 109 rim [0158] 111 sprocket assembly [0159] 112 pedal crank