Method of manufacturing a rim, rim, and tool device

Abstract

A manufacturing method for a fibrous composite bicycle rim, and a tool having two molding devices and one circular device. The two molding devices each have one flank contact surface. A molding device is selected and a matching auxiliary molding part is connected therewith, forming a mold surface for the rim base. A first fiber composite layer is applied to the molding device and the auxiliary molding part. The other molding device is covered with a first fiber composite layer, forming the layer of the other rim flank. A circular device is formed of annular segments has a circumferential rim well contact surface and is covered by a first fiber layer, which forms the rim well. The circular device and the molding devices are connected. The fibrous composite material is allowed to set, the annular segments and the molding devices are removed, and the rim is taken out.

Claims

1. A method of manufacturing a rim from a fibrous composite material, employing a tool device with a circular device and two molding devices comprising a left-side molding device and a right-side molding device, comprising the following steps: one molding device of the two molding devices is selected and provided, which comprises a flank contact surface to form a lateral rim flank; an auxiliary molding part of the tool device matching the selected molding device is connected with the selected molding device, so that the selected molding device together with the auxiliary molding part forms a mold surface for the rim base runs around an axis of symmetry of the rim, which is configured in sections on the selected molding device, and in sections, on the auxiliary molding part; a first fiber layer of the fibrous composite material is applied to the flank contact surface of the selected molding device, which, constituting a visible layer, forms at least a major part of the visible surface of the pertaining rim flank; wherein the first fiber layer is not only applied to the flank contact surface of the selected molding device, but also to the rim base region of the auxiliary molding part, to form a continuous first fiber layer in the region of the rim base; the auxiliary molding part is removed from the selected molding device; the other of the molding devices is provided, which comprises a flank contact surface to form the other, lateral rim flank; a first fiber layer of the fibrous composite material is applied to the flank contact surface of the other of the molding devices, which, constituting a visible layer, forms at least a major part of the visible surface of the other of the rim flanks; a plurality of annular segments are connected to form the circular device having a circumferential rim well contact surface, on which at least one first fiber layer of the fibrous composite material is applied, forming the rim well; the circular device is placed against one of the molding devices, and the other of the molding devices is placed against it, and the circular device and the molding devices are connected with one another; the fibrous composite material is allowed to set, and the annular segments and the molding devices are removed; and after removing the rim from the tool device, spoke holes are made.

2. The method according to claim 1, wherein the fiber layers are pressed against the molding devices of the tool device, to ensure full-surface contact between the fiber layers and the flank contact surfaces, and wherein all of the fiber layers, which form the visible outer surfaces as visible layers in use as intended, are pressed against the molding devices and the circular device of the tool device, to ensure full-surface contact between the fiber layers and the flank contact surfaces, and to prevent flaws on the visible surface, and to avoid refinishing work to the visible surface and in particular re-varnishing the outer surface to cover up air pockets and other flaws.

3. The method according to claim 2, wherein the first fiber layer applied to the selected molding device, forms the visible layer with the visible surface of the pertaining rim flank in the region of the flank contact surface, and in the rim base region of the auxiliary molding part, forms a reinforcement layer of the rim base but does not form the visible layer with the visible surface of the other of the rim flanks, and wherein the two molding devices and the auxiliary molding part each show a mold parting surface running perpendicular to the axis of symmetry of the rim, where they are selectively placed against one another.

4. The method according to claim 1, wherein at least one reinforcement layer is incorporated in the two interconnected molding devices.

5. The method according to claim 1, wherein rim flanges are configured on the two rim flanks, and wherein one rim flange is formed by fiber layers, which are applied to one of the molding devices and to the circular device, and wherein one fiber layer on at least one rim flange is folded over at the radially outwardly edge and is radially folded back inwardly.

6. The method according to claim 1, wherein all the visible surfaces on the finished rim are formed by the two molding devices and the circular device.

7. The method according to claim 1, wherein the circular device comprises at least two annular segments in the peripheral direction, and wherein the circular device comprises at least two annular segments in the axial direction transverse to the peripheral direction, wherein the axially central annular segments are configured in a wedge shape, and wherein a locking ring is placed on the outside around the interconnected molding devices and the circular device.

8. The method according to claim 1, wherein the tool device loaded with the fiber layers is evacuated, and wherein the tool device is inserted into a pressure device and heated.

9. The method according to claim 1, wherein prepregs are used for fiber layers, and wherein resin material is inserted.

10. The method according to claim 1, wherein an inflatable tube is inserted, prior to connecting the molding devices with the circular device, and wherein, after fastening the molding devices to the circular device, the tube is inflated.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The figures show in:

(2) FIG. 1 a schematic illustration of a mountain bike with rims according to the application;

(3) FIG. 2 a schematic illustration of a racing bicycle with rims according to the application;

(4) FIG. 3 a schematic total view of a tool device according to the application for manufacturing a rim according to the application;

(5) FIG. 4 an exploded view of the different components of the tool device according to FIG. 3;

(6) FIG. 5 a molding device and an auxiliary molding part of the tool device according to FIG. 4;

(7) FIG. 6 two sectional views of the tool device while manufacturing a rim;

(8) FIG. 7 a finished rim according to the application;

(9) FIG. 8 sectional views of the tool device and of the fiber layers of a rim while implementing the method according to the application;

(10) FIGS. 9-12 different sectional views while manufacturing rims according to the application; and

(11) FIG. 13 a schematic plan view of the circular device of the tool device according to FIG. 3.

DETAILED DESCRIPTION

(12) The FIGS. 1 and 2 each show a mountain bike respectively racing bicycle 100, each equipped with rims 1 according to the application. The mountain bike respectively racing bicycle 100 is provided with a front wheel 101 and a rear wheel 102, where rims 1 according to the application are employed. The two wheels 101, 102 are provided with spokes 109 connecting the rim 1 with the hubs 110. To this end, the rim 1 is provided with spoke holes 16.

(13) A bicycle 100 comprises a frame 103, a handlebar 106, a saddle 107, a fork or suspension fork 104 and in the case of the mountain bike, a rear wheel damper 105 may be provided. A pedal crank 112 with pedals serves for driving. Optionally, an electric auxiliary drive may be provided on the pedal crank 112 and/or the wheels. The hubs 110 of the wheels may be attached to the frame by means of a clamping system 49 (for example a through axle or a quick release).

(14) FIG. 3 shows the tool device 50 in the assembled state with the fiber layers already inserted to manufacture the rim 1, prior to inserting the tool device 50 into a separate pressure device, in which the tool device 50 is also heated to accelerate the hardening of the fibrous composite material. The tool device 50 is substantially configured rotationally symmetrical around an axis of symmetry 11, which at any rate forms an axis of symmetry for the finished rim 1.

(15) FIG. 4 shows an exploded view of the tool device 50, at the top of which a locking ring 90 is illustrated that is provided with a clamping portion 91 and a screw, not visible. The locking ring 90 may be placed around the further components of the tool device 50, and may serve as a clamping ring. Optionally, this locking ring 90 may be omitted.

(16) The bottommost component illustrated is a molding device 51, including a flank contact surface 52 which serves to form one of the two rim flanks of the rim 1 manufactured. The molding device 51 has fasteners 56 and configured or disposed thereat, alignment units 57, to which the molding device 51 with the circular device 80 and the other of the molding devices 61 is fastened by means of appropriate fasteners 56, or to the alignment units 57. The circular device includes alignment units 87, and the other of the molding devices 61 includes alignment units 67.

(17) As can be seen in FIG. 4, the circular device 80 or ring device 80 consists of a number of annular segments 81-83 extending in the peripheral direction around the central axis of symmetry 11. This allows separate removal of the annular segments.

(18) FIG. 5 shows a molding device 51 and the pertaining auxiliary molding part 70, which are interconnected to cover the flank contact surface 72 and the rim base regions 54 and 74 with fiber layers of the fibrous composite material. In this way, the region of the rim base is reinforced by one joint, continuous layer.

(19) The molding device 61 and the auxiliary molding part 70 are interconnected with, respectively placed on top of, one another on the mold parting surfaces 55 and 75.

(20) FIG. 6 shows two schematic illustrations of the tool device 50 and fiber layers 21-23 and 25 disposed therein. In the assembled state, the tool device substantially consists of a first molding device 51, a second molding device 61, and the circular device 80, which in turn consists (in the peripheral direction) of a number of annular segments 81-83 (see FIG. 4) and (in the axial direction) annular segments 85, 86.

(21) Optionally, the molding devices 51 and 61 may be configured multipart and may for example additionally comprise molding parts 51a and 61a. Preferably, however, each of the molding devices 51 and 61 is configured as one piece. The molding device 51 has a flank contact surface 52 for the rim flank 2 on the left, while the rim flank 3 on the right is formed by a (side wall) flank contact surface 62. The flank contact surfaces 52 respectively 62 are covered with fiber layers 21 respectively 22. Reinforcement layers 25 are also applied in the region of the rim base 4. The rim well 5 is formed by at least one fiber layer 23, which is applied radially inwardly on the circular device 80.

(22) The two rims 1 illustrated in FIG. 6 are each provided with rim flanges 6, 7, which are configured by fiber layers 21, 23 and 25. The outer surfaces 8 and 9 of the two rim flanks 2, 3, which will later be visible from the outside, are each formed by the first fiber layer 21 placed on the flank contact surface 52 and by the first fiber layer 22 placed on the flank contact surface 62. The visual range of the rim well is formed by the first fiber layer 23 placed on the circular device 80.

(23) All the visible surfaces respectively all the visible layers of the finished rim 1 are thus provided by the fiber layers 21-23, each of which is applied separately and full-surface on the molding devices 51 and 61, and the circular device 80. This achieves a particularly high surface quality, since air pockets or other flaws can be avoided better than in the prior art.

(24) To allow to apply pressure from the inside during hardening, a tube 32 (shown schematically only) is as a rule inserted, which can be guided outwardly through what is intended as the valve opening, and on which pressure can be applied after closing the tool device 50, to press each of the fiber layers 21-25 from the inside against the inner walls of the tool device 50. This secures a reliable composite. The tube 32 may be configured elastically, expanding when inflated. It is likewise possible and preferred for the tube 32 to be of sufficient size or matching configuration and with insertion, to be placed full-surface on at least one flank contact surface, and radially from the inside, placed full-surface on the circular device.

(25) Optionally it is possible, as can be seen on the right in FIG. 6, to insert peripheral rovings or fiber bundles 29 in the intersection of the rim flank 2, 3 with the rim well 5, to reinforce those regions and configure them still more robust.

(26) FIG. 7 shows a schematic illustration of a finished rim 1, comprising a rim base 4, a rim well 5, and rim flanks 2, 3, on which rim flanges 6, 7 are configured. A hollow space or hollow section 10 can be seen in the interior. The rim 1 is manufactured by way of a method according to the application and a tool device according to the application, of at least one fibrous composite material.

(27) FIG. 8 shows two schematic illustrations during manufacture. What is shown is, simplistic illustrations of the fiber layers in a tool device 50, wherein the outlines and the positions of the fiber layers 21-23 and 25 are shown intentionally roughly to give an illustrative example of the outlines of each of the fiber layers. In the illustration on the right in FIG. 8 it can be seen that the fiber layer 21 was not only placed onto the flank contact surface 52 of the molding device 51, but also onto the rim base region 74 of the auxiliary molding part 70, to form a reinforcement section 21a in the region of the rim well contact surface 62 of the other of the molding devices 61. Thus, an overlap of each of the fiber layers is enabled from one of the rim flanks to the other of the rim flanks in the region of the rim base.

(28) Circumferential rovings 29 are schematically shown, in the intersecting region 15 of the rim flanges 6, 7 with the rim well 5 respectively the rim flanks 2, 3 or side walls.

(29) In the lower region, the mold parting surfaces 55 and 65 (contact areas) of the two molding devices 51 and 61 can be seen, where the two molding devices 51 and 61 are joined together.

(30) FIG. 8 shows on the left, a pre-stage during manufacture of the rim 1 illustrated further to the right. FIG. 8 illustrates on the left, the state after connecting the selected molding device 51 with the auxiliary molding part 70, and placing fiber layers 21 and reinforcement layers 25 thereon, and after then removing the auxiliary molding part 70, and placing the circular device 80 on the selected molding device 51.

(31) This results in the layer structure visible on the left in FIG. 8, wherein due to the inherent stiffness of the prepregs 30 used for fiber layers 21-23 and 25, the protruding reinforcement section 21a and the correspondingly protruding regions of the fiber layers 25 (substantially) retain their shape. Thereafter, the other of the molding devices 61 can be placed onto the (selected) molding device 51 and the circular device 80, so that on the whole, a closed rim profile results for the rim 1. Then, in the region of the rim flange 7, the fiber layer 22 placed on the molding device 61 is pressed against the fiber layer 23 on the circular device 80. In the region of the rim base, the fiber layer 22 is pressed against the reinforcement section 21. Then, the tube 32 inflated in the further process in the interior of the hollow space 10 of the rim 1, reliably presses all the layers against one another and outwardly against the molding devices 51 and 62 and the circular device 80.

(32) The outer surfaces of the finished rim, which are particularly significant for the visual effect, are configured in a high quality, since what are the outside fiber layers 21, 22 and 23 forming the visible layers of the finished rim 1, are each separately pressed full-surface against the corresponding contact surfaces (flank contact surfaces 52, 62 and rim well contact surface 84).

(33) FIG. 9 shows the state during manufacture of a rim 1, after placing a first fiber layer 21 onto the rim contact surface 52 of the selected molding device 51 and the rim base region 74 of the auxiliary molding part 70. Furthermore, reinforcement layers 25 have been placed, contacting the mold surface 14 for forming of the rim base 4 and assuming the corresponding shape. In the FIG. 9 on the left, the mold parting surfaces (contact surfaces) 55 and 75 of the molding device 51 and of the auxiliary molding part 70 are still in contact with one another.

(34) In the radially outside region it can be seen that in the region of the rim flange 6, the fiber layer 21 has been folded over, forming a folded-over and radially inwardly extending section 21b for reinforcing the rim flange 6.

(35) Accordingly, the other of the molding devices 61 is also loaded with fiber layers 22, wherein the fiber layer 22 only extends over the flank contact surface 62. In this spot, a section 22b is likewise folded over in the region of the rim flange 7.

(36) Thereafter, the auxiliary molding part 70 is carefully removed, and the other of the molding devices 61 is approached with the mold parting surface 65 to the mold parting surface 55 of the (selected) molding device 51, where they are attached to one another. Preferably, however, this is done after placing the circular device 80 (not shown in FIG. 9) onto the selected molding device 51 (cf. e.g. FIG. 10).

(37) FIGS. 10 and 11 show various process steps in manufacturing a different rim having a different layer pattern, wherein FIG. 10 shows the state after placing fiber layers 21 and 25 on the rim contact surface 52 and the rim base region 74 of an auxiliary molding part, and then removing the auxiliary molding part 70. The protruding section 21a will later reinforce the rim base 4 in the region of the rim flank 3.

(38) FIG. 11 shows the next step in the manufacture of the rim 1 according to FIG. 10, wherein the other of the molding devices 61 has been placed on the circular device 80 and the selected molding device 51. Now the entire layer pattern, which is exemplarily drawn in, can be seen.

(39) FIG. 12 shows an intermediate step in the manufacture of another rim 1, wherein on the left, the fiber layers 21 and 25 are illustrated, which have been placed on the selected molding device 51 and the rim base region 74 of the auxiliary molding part 70, while on the right in the FIG. 12 are shown the fiber layer 22 and the other fiber layers placed on the flank contact surface 62 and the rim base region 64.

(40) FIG. 13 finally shows a schematic plan view of the circular device 80, where the three circumferentially disposed annular segments 81-83 can be seen.

(41) In all the configurations, the various fiber layers may be placed on top of one another at various angles relative to one another. Thus, in one layer the fibers (warp fibers or weft fibers of a woven material) may be aligned at 30, 60 or 45 to the peripheral direction of the finished rim. In a layer disposed on top thereof, the corresponding fibers may be aligned at another angle (e.g. another of the angles listed).

(42) On the whole, the invention provides an advantageous method and an advantageous tool device, with which to manufacture rims 1 having a reproducible, high quality. It is possible to provide a high surface quality of the outwardly visible surfaces, without complex refinishing work. An additional application of a varnish coat or varnish coating or the like is not required. This is made possible among other things by the fact that the outwardly visible layers of all the outside surfaces can be pressed immediately and directly on the corresponding mold surfaces of the tool device.

(43) The manufacturing method is simple and thus avoids defects, and reduces the reject rate.

(44) While a particular embodiment of the present method of manufacturing a rim, rim, and tool device 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

(45) 1 rim 2, 3 rim flank, rim side wall 4 rim base 5 rim well 6, 7 rim flange 8, 9 visible surface 10 hollow space 11 axis of symmetry 14 mold surface for forming the rim base 15 intersecting region 16 spoke hole 20 fibrous composite material 21 fiber layer, visible layer 21a reinforcement section 21b folded-over section 22 fiber layer, visible layer 22b folded-over section 23 fiber layer, visible layer 24 fiber layer 25 reinforcement layer 29 roving 30 prepreg 32 tube 41 pressing ring 42 pressing ring 50 tool device 51 molding device 51a molding unit 52 flank contact surface 54 rim base region 55 mold parting surface 56 fastener 57 alignment unit 61 molding device 61a molding unit 62 flank contact surface 64 rim base region 65 mold parting surface 67 alignment unit 70 auxiliary molding part 74 rim base region 75 mold parting surface 77 alignment unit 80 circular device, ring device 81-83 annular segments 84 rim well contact surface 85, 86 annular segments 87 alignment unit 90 locking ring 91 clamping portion 100 bicycle 101 wheel, front wheel 102 wheel, rear wheel 103 frame 104 fork, suspension fork 105 rear wheel damper 106 handlebar 107 saddle 109 spoke 110 hub 112 pedal crank