TOOL DEVICE FOR MANUFACTURING A RIM, AND RIM, AND USE

Abstract

A tool device and its use for manufacturing a bicycle rim, having opposite rim flanks, a rim well and a rim base and rim flanges configured on the radially outwardly ends of the rim flanks, wherein the tool device includes two molding devices and a circular device. The circular device forms the rim well and the axially inwardly oriented surfaces of the rim flanges. The circular device includes an annular unit of a less elastic material and at least one cover of a more elastic material. Alternately, the molding devices each include a molding unit of a less elastic material and at least one cover of a more elastic material, for attachment thereto. The thickness of the cover is between one eighth of the minimum wall thickness of the rim well of the rim manufactured and eight times the minimum wall thickness of the rim well of the rim manufactured.

Claims

1. A tool device for manufacturing a rim for at least partially muscle-powered vehicles and in particular bicycles, having opposite rim flanks, a rim well and a rim base, and rim flanges configured on the rim flanks, comprising: two molding devices and a circular device; wherein the molding devices each comprise contact surfaces for forming at least part of a rim flank and the external visible surface of the rim flanges; the circular device forms the rim well and the axially inwardly oriented surfaces of the rim flanges; the circular device comprises an annular unit, and the molding devices each comprise a molding unit; at least one of the units of an annular unit and molding units comprise a core of a less elastic material and at least one cover for attachment thereto, of a more elastic material; and the thickness of the cover is between one eighth of the minimum wall thickness of the rim well of the rim manufactured and eight times the minimum wall thickness of the rim well of the rim manufactured.

2. The tool device according to claim 1, wherein the circular device comprises an annular unit of a less elastic material and at least one ring cover of a more elastic material, and wherein the molding devices each comprise a molding unit of a less elastic material and at least one mold cover for attachment thereto of a more elastic material.

3. The tool device according to claim 1, wherein the thickness of the cover is between 0.16 mm and 6 mm.

4. The tool device according to claim 1, wherein the material of the ring cover and/or of the mold cover (51b, 61b) is configured more elastic than is the material of the annular unit and/or the molding devices.

5. The tool device according to claim 1, wherein in a radially inwardly region, the circular device comprises a contact surface for forming the rim well.

6. The tool device according to claim 5, wherein the circular device comprises two separate, axially spaced-apart pressing rings, which match the inner outline of the rim flange.

7. The tool device according to claim 1, wherein the ratio of the coefficient of elasticity of the materials of the annular unit and of the ring cover is higher than 2 or 5, and/or wherein the ratio of the coefficient of elasticity of the materials of the molding unit and of the mold cover is higher than 2 or 5.

8. The tool device according to claim 1, wherein the ring cover and the mold cover consist at least in part of a material taken from a group of materials comprising rubber-like materials and silicone materials.

9. The tool device according to claim 1, wherein the thickness of the ring cover and/or the mold cover is more than 0.5 mm and/or less than 5 mm.

10. The tool device according to claim 1, wherein the thickness of the ring cover is greater than half the axial width of the rim flange and/or less than three times the axial width of the rim flange.

11. The tool device according to claim 1, wherein for manufacturing two rims in different dimensions, the same annular unit may be employed by means of different ring covers.

12. A use of a tool device for manufacturing a rim for at least partially muscle-powered vehicles and in particular bicycles, wherein the tool device is configured according to claim 1.

13. A rim for at least partially muscle-powered vehicles and in particular bicycles with opposite rim flanks, a rim well and a rim base, where the rim flanks meet in the radially most inwardly point, manufactured from at least one fibrous composite material, using a tool device according to claim 1.

14. The rim according to claim 13, wherein the outer surface that is visible in operation as intended, is at least predominantly formed of the at least one fibrous composite material, and wherein the outer surface visible in operation as intended, does not, at least predominantly, comprise a varnish coat.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0093] The figures show in:

[0094] FIG. 1 a schematic illustration of a mountain bike with rims according to the application;

[0095] FIG. 2 a schematic illustration of a racing bicycle with rims according to the application;

[0096] FIG. 3 a schematic total view of a tool device according to the application for manufacturing a rim according to the application;

[0097] FIG. 4 an exploded view of the different components of the tool device according to FIG. 3;

[0098] FIG. 5 a molding device and an auxiliary molding part of the tool device according to FIG. 4;

[0099] FIG. 6 two sectional views of the tool device while manufacturing a rim;

[0100] FIG. 7 a finished rim according to the application;

[0101] FIG. 8 sectional views of the tool device and of the fiber layers of a rim while implementing the method according to the application;

[0102] FIGS. 9-12 different sectional views while manufacturing rims according to the application; and

[0103] FIG. 13 a schematic plan view of the circular device of the tool device according to FIG. 3.

DETAILED DESCRIPTION

[0104] 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.

[0105] 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).

[0106] 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.

[0107] 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.

[0108] The bottommost component illustrated is a molding device 51, including a flank contact surface 52 (side wall contact surface) which serves to form one of the two rim flanks of the rim 1 manufactured. The molding device 51 shows 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 80 comprises an annular unit 80a (forming a core 80a) and, in particular, a ring cover 40a (see FIG. 6), and comprises alignment units 87. The other of the molding devices 61 also comprises alignment units 67. Each of the two molding devices 51, 61 may consist of a molding unit 51a, 61a (core) and a mold cover 51b, 61b (see FIG. 11).

[0109] As can be seen in FIG. 4, the annular unit 80a of 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.

[0110] 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.

[0111] 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 (contact areas).

[0112] 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 comprises an annular unit 80a with a number of annular segments 81-83 (in the peripheral direction) (see FIG. 4) and (in the axial direction) annular segments 85, 86 and a ring cover 40a (ring cover unit 40a).

[0113] The ring cover 40a consists of a more elastic material than does the annular unit 80a (core of 80) and the molding devices 51, 61 or their molding units 51a, 61a (core of 51, 61). In this way, during hardening in the tool device 50, the regions of the rim flanges are pressed to the molding devices 51, 61 respectively the annular unit 80a, on one side by a more elastic material (ring cover 40a) and on the other side, by a less elastic material. Due to the heat generation during hardening and the thermal expansion, the pressure is further increased. The ring cover 40a consists, in particular, of a rubber material or rubber-like material, or preferably of a silicone or the like, or of a combination. The annular unit 80a and the molding devices 51, 61 are preferably manufactured of metal and, in particular, light metal.

[0114] Here, the ring cover 40a also covers the region of the rim well 5 on which pressure is applied from inside during hardening by way of the (inflatable) tube 32. The ring cover 40a acts against it from outside.

[0115] Optionally, the molding devices 51 and 61 may be configured multipart and may for example additionally comprise molding units (molding cores) 51a and 61a. Preferably, however, each of the molding devices 51 and 61 is configured as one piece (each forming a core), wherein separate mold covers 51b, 61b may be optionally provided (see FIG. 11). The molding device 51 shows 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.

[0116] 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. In the closed tool device, the elastic ring cover 40a applies pressure on the rim flanges.

[0117] 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 ring cover 40a of 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.

[0118] 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.

[0119] 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.

[0120] 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. FIG. 7 also shows the minimum wall thickness 5a of the rim base 5.

[0121] 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.

[0122] 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.

[0123] 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.

[0124] 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 removing the auxiliary molding part 70, and placing the circular device 80 with the annular unit 80a and the ring cover 40a on the selected molding device 51.

[0125] 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 ring cover 40a of 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 in the interior of the hollow space 10 of the rim 1 inflated in the further process, presses all of the layers reliably against one another and outwardly against the molding devices 51 and 62 and the ring cover 40a of the circular device 80.

[0126] 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). The rim flanges 6, 7 are manufactured in a particularly high quality, since the ring cover 40a provides for a suitable pressure.

[0127] 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.

[0128] 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.

[0129] 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.

[0130] 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 (illustrated above in FIG. 9) onto the selected molding device 51 (see e.g. FIG. 10).

[0131] The annular unit 80a of the circular device 80 is provided with a ring cover 40a (here, of a silicone material) in the contact areas with the manufactured rim 1. The ring cover 40a may, in the peripheral direction, be configured as one piece or consist of a number of segments. The elastic ring cover 40a reliably provides for a sufficient compacting pressure.

[0132] A wall thickness 43 respectively thickness of the ring cover 40a is drawn in, approximately corresponding to the wall thickness 6a, 6b in the region of the rim flank 2, 3 or of the rim flange 6, 7. The wall thickness 43 may be only half of what is shown, or it may measure 2 mm, 3 mm, 4 mm, or 5 mm or 6 mm. What is substantial is, that a sufficient shape retention and reproducibility of the wall thicknesses and surface quality of the rims 1 is achieved. In general terms, the wall thickness 43 respectively thickness of a cover 40 lies in the range of the (minimum or maximum) wall thickness of the rim.

[0133] The wall thickness 43 lies, in particular, in the range between ⅛ (or 1/10) and 8 times (or 10 times) the minimum wall thickness 5a of the rim base 5 and/or it may preferably lie between 0.1 mm and 10 mm. In particularly preferred configurations, the thickness 43 lies between 1 mm and 6 mm and particularly preferably e.g. around 4 mm+/−2 mm.

[0134] 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.

[0135] Shown in broken lines (dashed) and vertically hatched is an (optional) mold cover 51b on the molding unit 51a. The mold cover 51b consists of a more elastic material than does the molding unit 51a and e.g. of a rubber-like material or a silicone or the like. This makes the mold cover 51b (somewhat) compressible, and it can preferably reduce its thickness respectively wall thickness during manufacture by a few percentage points. It is conceivable to provide such a mold cover 51b in the region of the rim flanges only. The mold cover 51b may be provided alternatively or supplementarily to the ring cover 40a.

[0136] 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 with the ring cover 40a and the selected molding device 51. Now the entire layer pattern, which is exemplarily drawn in, can be seen.

[0137] Again, it is optionally possible for the molding device 61 to comprise a molding unit 61a and a mold cover 61b. Then the mold cover 61b provides the flank contact surface 62 overall or in the region of the rim flange.

[0138] It is also possible for the molding device 61 to comprise a molding unit 61a and a mold cover 61b, and for the circular device 80 to not comprise a ring cover 40a. At least in the region of the rim flanges, pressure is applied to the rim flange via the more elastic mold cover. The counterpressure is then applied directly by the annular unit 80a. Then, the circular device 80 may consist of the annular unit 80a only.

[0139] 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.

[0140] The circular device 80 respectively the annular unit 80a may—depending on the structural layout—be provided with two separate ring covers 41, 42, which are mounted separately in the region of the rim flanges 6, 7. Or, a completely continuous ring cover 40a is mounted, which covers both of the rim flanges 6, 7. Optionally, the circular device 80 may be employed for different widths of manufactured rims by way of (locally) different wall thicknesses of the ring cover 40a. It is also possible to employ three or more separate ring covers, e.g. ring covers 41 and 42 for the rim flanges, and a ring cover 40a for the rim well.

[0141] 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.

[0142] 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).

[0143] In the FIGS. 11 and 12, the wall thickness 43 respectively thickness 43 of a cover 40 (ring cover 40a or mold cover 51b or 61b) lies again in the range between 1/10 and 10 times the minimum wall thickness 5a of the rim base 5 and/or it may lie between 0.1 mm and 10 mm. Again, the thickness 43 lies, in particular, between 1 mm and 6 mm, e.g. around 4 mm+/−2 mm.

[0144] On the whole, the invention provides an advantageous method and an advantageous tool device, with which to manufacture rims 1 showing 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 layer 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.

[0145] The manufacturing method is simple and thus avoids defects, and reduces the reject rate.

[0146] While a particular embodiment of the present tool device for manufacturing a rim, and rim, and use 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.

TABLE-US-00001 List of reference numerals:  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 40 cover  40a ring cover  40b material of 40a, 51b, 61b 41 pressing ring 42 pressing ring 43 thickness 50 tool device 51 molding device  51a molding unit  51b mold cover 52 flank contact surface 54 rim base region 55 mold parting surface 56 fastener 57 alignment unit 61 molding device  61a molding unit  61b mold cover 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  80a annular unit, core  80b material of 80a 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