Composite material spoke array for bicycle wheel

Abstract

The invention relates to a composite spoke array for a bicycle wheel. A wheel for a bicycle includes a central hub, a rim, and a first array of spokes removably attached to the central hub and the rim. A first spoke array is located on a first side of the wheel and includes a first central flange and a plurality of first spokes integral with and extending away from the first central flange such that a first single part is formed. The wheel includes a second array of spokes removably attached to the central hub and a radially inner portion of the rim. The second array of spokes is located on a second side of the wheel. The second side of the wheel is opposite the first side of the wheel. The second spoke array includes a second central flange and a plurality of second spokes integral with and extending away from the second central flange such that a second single part is formed.

Description

TECHNICAL FIELD

[0001] The present disclosure relates generally to a bicycle wheel, and more particularly to a composite spoke array for a bicycle wheel. BACKGROUND

[0002] Conventional bicycle wheels can include a rim formed from extruded metal or other material that is bent and joined into a circular shape having a uniform cross-section. Alloy spokes are attached to the hub and the rim.

[0003] More recently, other materials, such as fiber-reinforced plastic, have been used in the manufacture of bicycle rims that can be formed into a circular shape by non-extrusion based processes. For example, carbon fiber-reinforced plastic can be used. SUMMARY

[0004] In one example, a wheel for a bicycle includes a center hub having a first end and a second end opposite the first end. The center hub is configured for rotational attachment to a bicycle. The wheel includes a rim including a radially inner portion disposed along an inner circumference of the rim, and a first spoke array removably attached to the center hub and the radially inner portion of the rim. The first spoke array is located on a first side of the wheel and includes a first center flange and a plurality of first spokes integral with and extending away from the first center flange such that a first single piece is formed. The wheel includes a second spoke array removably attached to the center hub and the radially inner portion of the rim. The second spoke array is located on a second side of the wheel. The second side of the wheel is opposite the first side of the wheel. The second spoke array includes a second center flange and a plurality of second spokes integral with and extending away from the second center flange such that a second single piece is formed.

[0005] In one example, the center hub includes a first flange and a second flange. The first flange is closer to the first end of the center hub than the second flange is to the second end of the center hub, and the second flange is closer to the second end of the center hub than the first flange is to the first end of the center hub. The first spoke array is removably attached to the first flange of the center hub, and the second spoke array is removably attached to the second flange of the center hub.

[0006] In one example, the first center flange and the plurality of first spokes of the first spoke array are made from a first material, and the second center flange and the plurality of second spokes of the second spoke array are made from a second material.

[0007] In one example, the first material and the second material are the same carbon fiber composite material.

[0008] In one example, the rim further includes a first sidewall and a second sidewall spaced apart from the first sidewall. The first sidewall and the second sidewall extend radially outward from the radially inner portion. The rim further includes a radially outer tire engaging portion disposed along an outer circumference of the rim. The radially outer tire engaging portion extends from the first sidewall and the second sidewall, respectively. The first sidewall, the second sidewall, the radially outer tire engaging portion, and the radially inner portion of the rim are made of a third material. The third material is a carbon fiber composite material.

[0009] In one example, the first central flange is a first polygonal ring and the second central flange is a second polygonal ring.

[0010] In one example, each of the first polygonal ring and the second polygonal ring has an inner surface shaped as a square, a pentagon, a hexagon, a heptagon, or an octagon.

[0011] In one example, the central hub further includes a first boss extending between the first flange and the first end and a second boss extending between the second flange and the second end. An outer surface of the first boss has a same shape as an inner surface of the first polygonal ring and an outer surface of the second boss has a same shape as an inner surface of the second polygonal ring.

[0012] In one example, the first boss includes a first retention feature at an outer surface of the first boss and the first polygonal ring includes a second retention feature at an inner surface of the first polygonal ring. The second retention feature is configured to interact with the first retention feature such that the first spoke array is attached to the central hub. The second boss includes a third retention feature at an outer surface of the second boss and the second polygonal ring includes a fourth retention feature at an inner surface of the second polygonal ring. The fourth retention feature is configured to interact with the third retention feature such that the second spoke array is attached to the central hub.

[0013] In one example, the first retention feature is a first detent feature extending into the first boss and the second retention feature is a second detent feature extending away from the inner surface of the first polygonal ring. The third retention feature is a third detent feature extending into the second boss and the fourth retention feature is a fourth detent feature extending away from the inner surface of the second polygonal ring.

[0014] In one example, a length of a first spoke of the plurality of first spokes extends between the first center flange and the rim. A length of a second spoke of the plurality of second spokes extends between the second center flange and the rim.

[0015] In one example, a spoke array removably attaches to a center hub and a rim of a wheel for a bicycle such that the spoke array forms all of the spokes of one side of the wheel. The spoke array includes a center flange and a plurality of spokes that are integral with and extend away from the center flange such that a single piece is formed.

[0016] In one example, the center flange and the plurality of spokes that are integral with the center flange are made of a carbon fiber composite material. The carbon fiber composite material includes a matrix of a polymeric base material and fibers of a reinforcing material. The fibers of the reinforcing material are carbon fibers.

[0017] In one example, a continuous fiber of the carbon fibers extends from a first spoke of the plurality of spokes to a second spoke of the plurality of spokes via the center flange.

[0018] In one example, the first spoke is angled relative to the second spoke.

[0019] In one example, the angle is an acute angle.

[0020] In one example, the center flange is a multi-sided ring having an inner surface shaped as a square, a pentagon, a hexagon, a heptagon, or an octagon.

[0021] In one example, the multi-sided ring includes a retention feature at the inner surface of the multi-sided ring.

[0022] In one example, the retention feature is a protrusion extending radially inward from the inner surface of the multi-sided ring.

[0023] In one example, the protrusion is a circumferential rib extending around a circumference of the inner surface of the multi-sided ring.

[0024] In one example, a spoke assembly for a bicycle includes a center hub having a first end and a second end opposite the first end. The center hub is configured for rotational attachment to the bicycle. The spoke assembly includes a spoke array removably attached to the center hub closer to the first end of the center hub than to the second end of the center hub. The spoke array includes a center flange and a plurality of spokes that are integral with and extend away from the center flange such that a single piece is formed.

[0025] In one example, the spoke array is a first spoke array, the center flange is a first center flange, the plurality of spokes is a first plurality of spokes, and the single piece is a first single piece. The spoke assembly further includes a second spoke array removably attached to the center hub. The second spoke array includes a second center flange and a plurality of second spokes that are integral with and extend away from the second center flange such that a second single piece is formed.

[0026] In one example, the center hub includes a first flange and a second flange. The first flange is closer to a first end of the center hub than to a second end of the center hub, and the second flange is closer to the second end of the center hub than to the first end of the center hub. BRIEF DESCRIPTION OF DRAWINGS

[0027] The objects, features and advantages of the present application will become apparent after review of the following drawings, in which:

[0028] Figure 1 is a schematic side view of a bicycle that can be configured to utilize a wheel that includes a spoke array;

[0029] Figure 2 is a perspective view of an embodiment of a wheel for a bicycle, such as Figure 1 the bicycle of

[0030] Figure 3 is a perspective view of an embodiment of a rim of a wheel, for example Figure 2 the wheel of

[0031] Figure 4 is a cross-section of Figure 3 the rim of

[0032] Figure 5 is a close-up perspective view of a portion of Figure 2 the wheel of

[0033] Figure 6 is a top view of a first example of a spoke array for a wheel for a bicycle, for example Figure 2 the wheel of

[0034] Figure 7 is a first close-up perspective view of Figure 6 the spoke array of

[0035] Figure 8 is a second close-up perspective view of Figure 6 the spoke array of

[0036] Figure 9 is a top view of a second example of a spoke array for a wheel for a bicycle, for exampleFigure 2 A close-up 3D view of the center hub of the wheel;

[0037] Figure 10 This is a cross-sectional view of the first side of the spoke assembly before the spoke array is attached to the center hub;

[0038] Figure 11 After the spoke array has been attached to the center hub Figure 10 A cross-sectional view of the spoke assembly;

[0039] Figure 12 After the spoke array has been attached to the center hub Figure 10 A perspective view of the second side of the spoke assembly;

[0040] Figure 13 This is a top view of a second example of a spoke array;

[0041] Figure 14 This is a top view of the third example of a spoke array;

[0042] Figure 15 This is a top view of the fourth example of a spoke array;

[0043] Figure 16 This is a top view of the composite material strip;

[0044] Figures 17A to 17D Different examples of continuous fiber paths are shown;

[0045] Figure 18 This is a flowchart of an embodiment of a method for manufacturing wheel rims;

[0046] Figure 19 It is for bicycles (e.g.) Figure 1 A cross-sectional view of the rim of a bicycle (in the image).

[0047] Figure 20 Spokes and rim (e.g.) Figure 19 A close-up view of the interface of the wheel rim (in the image);

[0048] Figure 21 It is an interface structure (e.g.) Figure 19 The first embodiment of the interface structure shown;

[0049] Figure 22 This is the second embodiment of the interface structure;

[0050] Figure 23 This is the third embodiment of the interface structure; and

[0051] Figure 24 This is the fourth embodiment of the interface structure. Detailed Implementation

[0052] Carbon spokes are lighter than alloy spokes. However, carbon spokes are difficult to attach to a rim or hub for a wheel of a bicycle in a modular or replaceable manner.

[0053] The present disclosure provides examples of carbon composite spoke arrays and wheels including such spoke arrays. Carbon composite spoke arrays provide modularity and are easy to replace. For example, a bicycle wheel is provided that includes two composite spoke arrays forming spokes on opposite sides of the bicycle wheel. Each of the composite spoke arrays includes composite spokes arranged to structurally intersect a polygonal ring about an axis of rotation of a hub of the bicycle wheel. The composite spokes can be secured to the rim in a variety of ways including, for example, threaded interface with a fitting secured in the rim.

[0054] The polygonal ring of the composite spoke array interfaces with the hub such that the spoke array can be removed and replaced with standard tools. The polygonal ring can be formed at least partially as a continuation of the body of the composite spokes into a geometry that interfaces with the hub. The interface between the polygonal ring and the hub resists torque transmitted between the hub and the spoke array.

[0055] Examples address or improve one or more of the aforementioned and / or other concerns. The disclosed spoke arrays, for example, provide modularity and ease of repair. In addition, the disclosed spoke arrays can be lighter than a corresponding number of alloy spokes. The disclosed spoke arrays allow spoke preload forces to be transmitted across the hub without relying on the hub material to support the preload forces, which can allow weight reduction of the wheel. The disclosed spoke array forming all of the spokes of one side of the wheel reduces assembly time and complexity of the wheel.

[0056] Turning now to the drawings, Figure 1 A bicycle 50 employing a wheel constructed in accordance with the teachings of the present disclosure is shown generally. Bicycle 50 includes a frame 52, front and rear wheels 54 and 56 rotatably attached to frame 52, and a drive train 58. A front brake 60 is provided for braking front wheel 54, and a rear brake 62 is provided for braking rear wheel 56. Bicycle 50 also typically has a saddle 64 near a rear end of frame 52, saddle 64 carried on an end of a saddle tube 66 connected to frame 52. Bicycle 50 also has handlebars 68 near a front end of frame 52. A brake lever 70 is carried on handlebars 68 for actuating front brake 60, rear brake 62, or both front and rear brakes 60 and 62. If brake lever 70 actuates only one of front and rear brakes 60 and 62, a second brake lever (not shown) can also be provided to actuate the other brake. The front and / or forward riding direction or orientation of bicycle 50 is indicated by arrow 71. Figure 1The direction of arrow A is indicated by the arrow. Therefore, the forward direction of bicycle 50 is indicated by the direction of arrow A. Although Figure 1 The bicycle 50 depicted is a road bicycle with drooping handlebars 68, but this disclosure is applicable to any type of bicycle, including mountain bikes with full or partial suspension.

[0057] The drivetrain 58 has a chain C and a front sprocket assembly 72, which is coaxially mounted with a crank assembly 74 having pedals 76. The drivetrain 58 also includes a rear sprocket assembly 78 coaxially mounted with the rear wheel 56 and a rear shift mechanism (e.g., a rear derailleur 80).

[0058] like Figure 1 As shown, the front sprocket assembly 72 may include one or more coaxially mounted chain links, gears, or sprockets. In this example, the front sprocket assembly 72 has at least one front sprocket F (e.g., a single front sprocket). The front sprocket F has teeth 82 around its respective circumference. Figure 1 As shown, the rear sprocket assembly 78 may include a plurality of coaxially mounted gears, cogs, or sprockets G. Each rear sprocket G1-G11 also has teeth 84 arranged around its respective circumference. The number of teeth 84 on the rear sprockets G1-G11 can gradually decrease from the rear sprocket G1 with the largest diameter to the rear sprocket G11 with the smallest diameter. Although not described in detail here, the front shifter 85 can be operated to move from a first operating position to a second operating position to move the chain C between the front sprockets F. Similarly, the rear derailleur 80 can be operated to move between different operating positions to switch the chain C to a selected one of the rear sprockets G1-G11. In embodiments, the rear sprocket assembly 78 may have more or fewer sprockets G. For example, in an embodiment, the rear sprocket assembly 78 may have twelve or thirteen sprockets. The size and construction of the rear derailleur 80 can be modified to accommodate the multiple sprockets of a particular implementation. For example, the angle and length of the linkage mechanism and / or the construction of the cage of the rear derailleur 80 can be modified to accommodate a specific sprocket combination.

[0059] The rear derailleur 80 is depicted as a wireless, electrically actuated rear derailleur mounted or mountable to a frame 52 or frame attachment of the bicycle 50. The electric rear derailleur 80 has a base member 86 (e.g., a b-shaped knuckle) mounted to the bicycle frame 52. A linkage 88 has two links L pivotally connected to the base member 86 at a base member linkage connection. A movable member 90 (e.g., a p-shaped knuckle) is connected to the linkage 88 at a movable member linkage connection. A chain guide assembly 92 (e.g., a cage) is configured to engage the chain and maintain tension in the chain and has one or more cage plates 93 having a proximal end pivotally connected to a portion of the movable member 90. The cage plates 93 can rotate or pivot about a cage rotation axis in a dampening direction and a chain tensioning direction. Other shifting systems can also be used, such as mechanically or hydraulically controlled and / or actuated systems.

[0060] An electric motor module can be carried on the electric rear derailleur 80 with a battery. The battery powers the electric motor module. In one example, the electric motor module is located in the movable member 90. However, the electric motor module can alternatively be located elsewhere, such as in one of the links L of the linkage 88 or in the base member 86. The electric motor module can include a gear mechanism or transmission. The electric motor module and gear mechanism can couple with the linkage 88 to move the cage plates 93 laterally, and thus shift the chain C between the rear sprockets (e.g., G1-G11) on the rear sprocket assembly 78, as known in the art.

[0061] The cage plates 93 also have a distal end carrying a tensioner cog or wheel. The wheel also has teeth around a circumference. The cage plates 93 are biased in the chain tensioning direction to maintain tension in the chain C. The chain guide assembly 92 can also include a second cog or wheel, such as a guide wheel disposed closer to the proximal end of the cage plates 93 and the movable member 90. In operation, the chain C is routed around one of the rear sprockets (e.g., G1-G11). An upper segment of the chain C extends forward to the front sprocket assembly 72 and is routed around one front sprocket F. A lower segment of the chain C returns from the front sprocket assembly 72 to the tensioner wheel and is then directed forward to the idler wheel. The idler wheel directs the chain C to the rear sprockets (e.g., G1-G11). Lateral movement of the cage plates 93, the tensioner wheel, and the guide wheel can determine the lateral position of the chain C to align with a selected one of the rear sprockets (e.g., G1-G11).

[0062] Bicycle 50 may include one or more bicycle control devices mounted to handlebars 68. The bicycle control devices may include one or more types of bicycle control and / or actuation systems. For example, the bicycle control devices may include brake actuation systems for controlling the front brake 60 and / or the rear brake 62, and / or shifting systems for controlling the drivetrain 58. Other control systems may also be included. For example, in some embodiments, the system may be applied to bicycles using only a front derailleur or only a rear derailleur. Furthermore, the one or more bicycle control devices may also include suspension control systems, seatpost control systems, and / or other control systems for bicycle 50.

[0063] The front wheel 54 and / or rear wheel 56 of the bicycle 50 may include a tire 120 attached to the radially outer tire engagement portion of the rim 122. The tire 120 can be of any number and size. For example, the tire 120 may have a width greater than 34 mm. Figure 1 and Figure 2 As shown, multiple spokes 124 are directly attached to the rim 122 (e.g., via a threaded interface with a metal connector fixed in the rim 122). Alternatively, the spokes 124 can be attached and / or secured to the rim 122 using other structural components. The spokes 124 extend from the rim 122 and are attached to the center hub 126. The spokes 124 are held at tension between the rim 122 and the center hub 126 to provide operational rigidity for the respective front wheel 54 and rear wheel 56 on the bicycle 50. The center hub 126 is configured to be rotatably attached to the bicycle frame 52.

[0064] Figure 2 A bicycle wheel with a rim 122, spokes 124, and a center hub 126 is shown, such as Figure 1 The front wheel 54 is removed from the rest of the bicycle 50 and is not attached to a tire. The rim 122 includes components for connecting to the tire 120 (such as...). Figure 1 (As shown) The tire engagement portion 130 is engaged. The tire engagement portion 130 is configured radially outward of the spoke receiving surface 132, which is disposed along the inner circumference 134 of the rim 122. In other words, the tire engagement portion 130 is a radially outward tire engagement portion. In an embodiment, the tire engagement portion 130 is disposed along the outer circumference 135 of the rim 122. The tire engagement portion 130 is configured to attach to a tubeless tire. Other configurations of the tire engagement portion 130 may be provided for a clamping tire attachment configuration of a tire including a bead interlock attachment. Other configurations of the tire engagement portion 130 may also be provided to allow the use of other types of tires on the rim 122. For example, a tubeless tire including a bead interlock attachment type may be used.

[0065] The rim 122 provides structure for attaching the spokes 124 to the rim 122 at a receiving portion of the rim 122 proximate the rim receiving surface 132. Thus, the spoke receiving surface 132 is part of a spoke engagement portion 136 (e.g., a radially inner portion) of the rim 122. In an embodiment, the spoke engagement portion 136 of the rim 122 is disposed along the inner circumference 134 of the rim 122. In another embodiment, the spoke receiving surface 132 and the spoke engagement portion 136 can be separate pieces and / or portions of the rim 122. For example, the spokes 124 can pass through the spoke receiving surface 132 and the structure for attaching to the rim 122 can be disposed proximate the tire engagement portion 130.

[0066] In Figure 19 and Figure 20 embodiment 1000, the spoke engagement portion 136 of the rim 122 includes the spoke receiving surface 132 having a rim-spoke interface 1003. The spoke 124 is received within a spoke interface structure 1001 of the rim-spoke interface 1003. The spoke interface structure 1001 is at least partially located within the rim 122. The spoke interface structure 1001 is at least partially located at the inner circumference 134 of the rim 122. The spoke interface structure 1001 is at least partially located on the inner side of the rim 122 at the spoke receiving surface 132. The spoke interface structure 1001 is at least partially located outside of the rim 122 at the spoke receiving surface 132.

[0067] In Figure 20 example, the spoke interface structure 1001 includes a spoke joint 1002. In this example, the spoke joint 1002 rests on the inner side of the rim 122 at the spoke receiving surface 132. The spoke interface structure 1001 includes a spoke engagement structure 1004. In this example, the spoke engagement structure 1004 has a first end that interfaces with or connects to the spoke joint 1002. The spoke engagement structure 1004 has a second end that receives the spoke 124. When the bicycle wheel is assembled, at least a portion of the spoke engagement structure 1004 passes through a spoke hole 1020 of the rim 122 such that the spoke joint 1002 is within the rim 122 and the second end of the spoke engagement structure 1004 is outside of the rim.

[0068] As shown in Figure 21 , the second end of the spoke engagement structure 1004 includes an opening 1012. The opening 1012 allows the spoke 124 to enter a chamber 1010 that is sized and shaped to receive an end 1014 of the spoke 124. In Figure 21In the example, at least some of the adhesive 1008 secures the end 1014 of the spoke 124 to the spoke joint structure 1004. At least some of the adhesive 1008 is present between the inner surface of the chamber 1010 and the end 1014 of the spoke 124 to secure the spoke 124 within the chamber 1010.

[0069] In this embodiment, the adhesive can be any type of adhesive capable of securing the end 1014 of the spoke 124 within the chamber 1010. For example, adhesives such as glue, tape, natural oils, and liquid adhesives can be used.

[0070] Alternative embodiment 2000 of spoke interface structure 2001 is in Figure 22 As shown in [the image]. Figure 22 In one embodiment, the spoke engagement structure 2004 includes an opening 2012 for the spoke 2224 to travel into the chamber 2010. The inner surface of the chamber 2010 includes threads 2006. The threads 2006 of the chamber 2010 thread-engage with threads 2008 at the end 2014 of the spoke 2224. The spoke 2224 is screwed into the spoke engagement structure 2004 to secure the spoke 2224 to a bicycle rim, such as rim 122.

[0071] exist Figure 23 In the alternative embodiment 3000 of the spoke interface structure 3001 shown, the length of the spoke joint structure 3004 is shorter than... Figure 22 The spoke engagement structure 2004 is shown. The spoke interface structure 3001 includes a tension adjusting element 3008 at the second end of the spoke engagement structure 3004. The tension adjusting element 3008 includes an opening 3012 for receiving a spoke 2224. The tension adjusting element 3008 is threadedly engaged with a thread 2008 at the end 2014 of the spoke 2224. When rotating, the tension adjusting element 3008 can adjust the tension of the spoke 2224.

[0072] The tension adjusting element 3008 may be a hexagonal nut or other structure. In one embodiment, the tension adjusting element 3008 may be integrated with the spoke engagement structure 3004 as a single piece. In an alternative embodiment, the tension adjusting element 3008 may be a separate component from the spoke engagement structure 3004.

[0073] Alternative embodiment 4000 of spoke interface structure 4001 is in Figure 24 As can be seen, the difference between spoke joint structure 4001 and spoke joint structure 3001 is that the tension adjustment element 4008 is located on top of spoke joint 4002, rather than at the second end of spoke joint structure 2004.

[0074] The tension adjustment element 4008 can be a hex nut or other structure. In embodiments, the tension adjustment element 4008 can be integrated with the spoke nipple 4002 as a single piece. In alternative embodiments, the tension adjustment element 4008 can be a separate component from the spoke nipple 4002.

[0075] In embodiments, the tension adjustment element 3008 and / or 4008 can be configured to be turned individually or in combination with the rest of the spoke interface structure 3001 and / or 4001 in order to adjust the spoke tension. In embodiments, a tool can be used in order to turn the tension adjustment element 3008 and / or 4008. In alternative embodiments, no tool can be required to turn the tension adjustment element 3008 and / or 4008. The tension adjustment element 3008 and / or 4008 can include a tool interface. In Figure 2 In embodiments, the rim 122 includes a first sidewall 138 and a second sidewall extending between the tire engagement portion 130 and the spoke engagement portion 136. For example, the first sidewall 138 and the second sidewall extend radially outward from the spoke engagement portion 136 to the tire engagement portion 130. The first sidewall 138 is spaced apart from the second sidewall.

[0076] The rim 122 can be made from any number of materials. For example, the rim 122 can be made from a metal (e.g., aluminum or an aluminum alloy). In one embodiment, at least a portion of the rim 122 (e.g., the spoke engagement portion 136 and / or the tire engagement portion 130) is formed from one or more composite materials (e.g., a carbon fiber composite material). In one embodiment, the entire rim 122 is formed from two or more composite materials. Other configurations can also be provided. For example, a combination of a first composite material and a second composite material form a single-piece monolithic rim having a series of first composite material layers and second composite material layers, the single-piece monolithic rim including the tire engagement portion 130, the first sidewall 138, the second sidewall, and the spoke engagement portion 136.

[0077] The front wheel 54 and the rear wheel 56 can include a rim 122 configured for any size wheel. In embodiments, the rim 122 is configured for use in a wheel that complies with a wheel standard.

[0078] The front wheel 54 and the rear wheel 56 can rotate in either direction about the central hub 126. For example, as shown in FIG. 1, the front wheel 54 and the rear wheel 56 can be configured to rotate in a particular rotational direction about the central hub 126. In another example, the front wheel 54 and the rear wheel 56 can be configured to rotate in a direction opposite the particular rotational direction. Figure 2

[0079] ​During manufacturing, for each of the rims 122 (e.g., rims for the front wheel 54 and the rear wheel 56), a layer of at least one composite material forming the first sidewall 138 and the second sidewall can be integrated with a layer of one or more composite materials forming the spoke joint portion 136 and the tire joint portion 130 of the respective front wheel 54 and rear wheel 56. A single-piece integral rim 122 can then be formed using, for example, a curing process. The rims 122 for the front wheel 54 and the rear wheel 56 can be formed using other manufacturing processes, respectively.

[0080] refer to Figure 2 The plurality of spokes 124 include a first spoke 124a at a first side 160 of the respective front wheel 54 and rear wheel 56, and a second spoke 124b at a second side 162 of the respective front wheel 54 and rear wheel 56. The first spoke 124a together with a first flange 164 (e.g., a first multifaceted ring) forms a first spoke array 166, and the second spoke 124b together with a second flange 168 (e.g., a second multifaceted ring) forms a second spoke array 170. Both the first spoke array 166 and the second spoke array 170 are single components. The first spoke array 166 and the second spoke array 170 are removably attached to the center hub 126 at or near opposite sides of the center hub, respectively.

[0081] Figure 3 and Figure 4 An embodiment of a rim 200 is shown. In one embodiment, a laminate pattern of composite material layers for the rim is provided prior to, for example, a curing process for forming the rim 200. After the curing process, the composite material layers may be part of a one-piece integral rim 200. The resulting one-piece integral rim 200 may be formed from a composite laminate comprising one or more compressed layers of one or more composite materials. In another embodiment, the rim 200 is at least partially made of a metal such as aluminum or an aluminum alloy. In other embodiments, the rim 200 may be made of different, additional, and / or fewer materials.

[0082] Composite laminates may include any number of composite materials. For example, one or more composite materials in a composite laminate may include a first composite material, a second composite material, a third composite material, or any combination thereof. Composite laminates may include more or fewer composite materials. For example, a composite laminate may contain only the first and second composite materials, or it may contain only the second and third composite materials. In one embodiment, a composite laminate may include only the first composite material, only the second composite material, or only the third composite material.

[0083] The first composite material can include a matrix of a polymeric base material (e.g., a first polymeric base material) and fibers of a reinforcing material (e.g., a first reinforcing material). The first polymeric base material can be any number of materials including, for example, plastic, acrylic, resin, epoxy, or any combination thereof, and the fibers of the first reinforcing material can be any number of materials including, for example, carbon. Other polymeric base materials and / or other reinforcing fibers can be used.

[0084] The second composite material can include a matrix of a polymeric base material (e.g., a second polymeric base material) and fibers of a reinforcing material (e.g., a second reinforcing material). The second polymeric base material can be any number of materials including, for example, plastic, acrylic, resin, epoxy, or any combination thereof, and the fibers of the second reinforcing material can be any number of materials including, for example, fiberglass. Other polymeric base materials and / or other reinforcing fibers can be used.

[0085] The third composite material can include a matrix of a polymeric base material (e.g., a third polymeric base material) and fibers of a reinforcing material (e.g., a third reinforcing material). The third polymeric base material can be any number of materials including, for example, plastic, acrylic, resin, epoxy, or any combination thereof, and the fibers of the third reinforcing material can be any number of materials including, for example, natural fibers. For example, the fibers of the third reinforcing material can be flax fibers, kenaf fibers, hemp fibers, jute fibers, or sisal fibers. Other polymeric base materials and / or other reinforcing fibers can be used.

[0086] The rim 200 includes a radially outer tire engagement portion 202 (e.g., disposed along an outer circumference of the rim 200), a radially inner portion 204 (e.g., a spoke engagement portion), a first side wall 206, and a second side wall 208 spaced apart from the first side wall 206. The first side wall 206 and the second side wall 208 extend radially outward from the radially inner portion 204 to the radially outer tire engagement portion 202. The radially outer tire engagement portion 202 extends from the first side wall 206 and the second side wall 208, respectively.

[0087] The radially outer tire engagement portion 202 of the rim 200 includes a first tire retention portion 210 and a second tire retention portion 212 spaced apart from the first tire retention portion 210. The first tire retention portion 210 extends from the first side wall 206, and the second tire retention portion 212 extends from the second side wall 208.

[0088] The first tire retention portion 210 includes a first tire retention wall 214. In an alternative embodiment, the first tire retention portion 210 also includes a first protrusion (e.g., a first tire retention feature) (not shown). The first protrusion can extend away from the first tire retention wall 214. The first protrusion can be any number of shapes, including, for example, a shape with a cross-section that is a rectangular with a semi-circular cap. The first protrusion can extend circumferentially around the rim 200. The second tire retention portion 212 includes a second tire retention wall 216. The second tire retention wall 216 is opposite and spaced apart from the first tire retention wall 214. In an alternative embodiment, the second tire retention portion 212 also includes a second protrusion (e.g., a second tire retention feature) (not shown). The second protrusion can extend away from the second tire retention wall 216 toward the first tire retention portion 210. The second protrusion can be any number of shapes, including, for example, a shape with a cross-section that is a rectangular with a semi-circular cap. The second protrusion can extend circumferentially around the rim 200. The first protrusion and the second protrusion can be other shapes.

[0089] The rim 200 can seat a tire 120 (see Figure 1 ), i.e., for example, a tubeless tire. The tire 120 can include a bead that interacts with the radially outer tire engagement portions 202 (e.g., the first tire retention portion 210 and the second tire retention portion 212) of the rim 200 to attach the tire 120 to the rim 200 and to retain the tire 120 on the rim 200. The bead can include any number of materials within the bead - for example, steel wire or aramid (e.g., Kevlar TM ) fibers - to prevent the tire 120 from coming off of the rim 200. For example, due to the reinforcement with steel wire or Kevlar TM fibers, the bead resists stretching from internal air pressure. Alternatively, the bead can be made of the same material as the tire 120 (e.g., rubber).

[0090] The radially outer tire engaging portion 202 also includes a pocket 218 positioned between the first tire retention portion 210 and the second tire retention portion 212 of the rim 200. The pocket 218 provides a volume in which the beads of the tire 120 can be placed when the tire 120 is being attached to the rim 200. As the tire 120 is inflated, the beads of the tire 120 move away from each other until the beads interact with the first tire retention portion 210 and the second tire retention portion 212, respectively. When inflated, the beads of the tire 120 abut the first tire retention wall 214 and the second tire retention wall 216, respectively. In one embodiment, for example, the first tire retention feature and the second tire retention feature retain the beads of the tire 120 within the radially outer tire engaging portion 202 (e.g., retain the beads of the tire 120 in engagement with the first tire retention wall 214 and the second tire retention wall 216), thereby preventing the tire 120 from blowing off of the rim 200. The contact between the beads and the first tire retention wall 214 and the second tire retention wall 216, respectively, forms a seal between the inflated tire 120 and the rim 200.

[0091] The radially outer tire engaging portion 202 can also include ridges (e.g., bead bumps: a first bead bump and a second bead bump) positioned on opposite sides of the pocket 218, respectively. A first shelf 220 (e.g., a first bead shelf) extends away from the first tire retention wall 214 (e.g., between the first tire retention wall 214 and the first bead bump), and a second shelf 222 (e.g., a second bead shelf) extends away from the second tire retention wall 216 (e.g., between the second tire retention wall 216 and the second bead bump). In one embodiment, a curved transition region 224 extends between the first shelf 220 and the first tire retention wall 214 and between the second shelf 222 and the second tire retention wall 216, respectively. The bead bumps can be positioned on opposite sides of the pocket 218, respectively, and can be elevated relative to the first shelf 220 and the second shelf 222, respectively. If the tire 120 loses pressure, the bead bumps can help retain the tire 120 on the rim 200.

[0092] In one embodiment, the layer of one or more composite materials (e.g., a first composite material, a second composite material, and / or a third composite material) is shaped as a strip. The strip of composite material (e.g., a first composite material) of the one or more composite materials can include fibers that extend along a limited length of the strip. In one embodiment, the fibers extend in a primary strength direction of the strip (e.g., along the length of the strip). For example, the strip has a unidirectional fiber orientation along the length of the strip. In another embodiment, some fibers do not extend in the primary strength direction (e.g., less than 20% of the fibers, less than 10% of the fibers, or less than 5% of the fibers).

[0093] The strip can be any number of shapes and / or sizes. For example, the strip is rectangular in shape. Other shapes can be provided, such as square strips and non-rectangular parallelogram strips. The strip also includes a width that is perpendicular to the length of the strip. The length of the strip can be defined by the dimensions of the radially outer tire engaging portion 202, the first sidewall 206, the second sidewall 208, and / or the radially inner portion 204 of the wheel rim 200, for example. In other words, the length of the strip can be at least as tall or as wide as the radially outer tire engaging portion 202, the first sidewall 206, the second sidewall 208, and / or the radially inner portion 204 of the wheel rim 200. In one embodiment, the width of the strip is between 10 mm and 50 mm. For example, the width of the strip is 30 mm. In other embodiments, the strip is wider or narrower (e.g., 60 mm). Smaller strip widths better optimize fiber orientation, but at the cost of increased manufacturing complexity. In one embodiment, the width of the strip is as wide as the radial width of the wheel rim 200.

[0094] Layers of different shapes, greater widths, and / or greater lengths can be used. For example, at least some of the layers of the first composite material can extend around the wheel rim 200 a quarter, a half, or all of the way around. For example, different sizes and / or shapes of layers of the first composite material can be used depending on the application within the wheel rim 200 (e.g., forming an outer surface, providing strength and stiffness at high load locations within the wheel rim).

[0095] The layer or layers of composite material can have any number of thicknesses. For example, the layer or layers of composite material can be 0.4 mm or less thick (e.g., 0.25 mm or less). Other thicknesses of the layer or layers of composite material can be provided.

[0096] For example, for one or more portions of the wheel rim 200, each of the plurality of layers of composite material (e.g., the second composite material) in the one or more composites can be unidirectional. The plurality of layers of composite material can be stacked and stitched together such that a checkered or hash pattern is formed within the layer. In other words, at least some of the plurality of layers of composite material are unidirectional in different directions. The thickness of such layers can be 1.2 mm or more. Other thicknesses can be provided.

[0097] Figures 5 to 12A first embodiment of a spoke array 300 is shown, which is removably attached to a center hub (e.g., center hub 126) of a wheel (e.g., front wheel 54 or rear wheel 56) of a bicycle (e.g., bicycle 50). The spoke array 300 forms all of the spokes of one side (e.g., first side 160 or second side 162) of the wheel of the bicycle. The spoke array 300 includes a center flange 302 and a plurality of spokes 304, which are integral with and extend away from the center flange 302, such that a single part is formed.

[0098] The plurality of spokes 304 can include any number of spokes 304. For example, as shown, the plurality of spokes 304 can include ten spokes that are integral with and extend away from the center flange 302. In other embodiments, the plurality of spokes 304 can include more or fewer spokes 304. Figures 5 to 12

[0099] The plurality of spokes 304 and the center flange 302 can be made of any number of materials (e.g., one or more materials). The one or more materials can include a first composite material. In one embodiment, alternatively or additionally, the one or more materials include a second composite material, a third composite material, and / or one or more other materials (e.g., a metal, such as an alloy).

[0100] In one embodiment, the plurality of spokes 304 and the center flange 302 are made of the same material (e.g., the first composite material). In another embodiment, the plurality of spokes 304 and the center flange 302 are made of different materials (e.g., the first composite material and the second composite material, respectively). In yet another embodiment, a subset of the plurality of spokes 304 are made of different materials.

[0101] Each spoke of the plurality of spokes 304 extends away from the center flange 302. The plurality of spokes 304 can be curved or straight. In one embodiment, a first portion of a spoke of the plurality of spokes 304 is curved and a second portion of the spoke of the plurality of spokes 304 is straight. A length L of each spoke of the plurality of spokes 304 is defined by a distance that extends along the respective spoke away from the center flange 302 to an end 306 of the respective spoke 304. In one embodiment, all of the spokes of the plurality of spokes 304 have the same length L. In another embodiment, at least some of the spokes of the plurality of spokes 304 have different lengths L, respectively.

[0102] For example, the center flange 302 can be a multi-faceted ring having any number of different shapes. The multi-faceted ring 302 can have one or more inner surfaces 308, one or more outer surfaces 310, a first side 312 (e.g., a top side), and a second side 314 (e.g., a bottom side) opposite the first side 312.​

[0103] For example, referring to Figure 7 , the polygonal ring 302 can be shaped as a pentagon, and thus has five inner surfaces 308 (e.g., with a circular transition 315 between adjacent ones of the five inner surfaces 308) and five outer surfaces 310. As described below, different shapes of polygonal rings 302 can be provided.

[0104] Figures 6 to 11 The first embodiment of the spoke array 300 illustrates an example of a spoke pattern 316. Within the spoke pattern 316, pairs of spokes 304 cross such that triangles 318 (e.g., five triangles) are formed from the five outer surfaces 310, respectively. The triangles 318 formed by the pairs of spokes combine with the polygonal ring 302 shaped as a pentagon to form a star shape. Such a spoke pattern 316 can provide strength to the wheel. In other embodiments, other spoke patterns can be provided.

[0105] Referring to Figure 5 and Figures 9 to 12 , the center hub 126 has a first end 320 and a second end 322 opposite the first end 320. The center hub 126 includes a first flange 324 proximate the first end 320 of the center hub 126 (e.g., closer to the first end 320 of the center hub 126 than to the second end 322 of the center hub 126), and a second flange 326 proximate the second end 322 of the center hub 126 (e.g., closer to the second end 322 of the center hub 126 than to the first end 320 of the center hub 126). The center hub 126 further includes a first boss 328 extending away from the first flange 324 between the first flange 324 and the first end 320 of the center hub 126, and a second boss 330 extending away from the second flange 326 between the second flange 326 and the second end 322 of the center hub 126.

[0106] The size and shape of the first boss 328 (e.g., the size and shape of the outer periphery) can correspond to the size and shape defined by one or more of the inner surfaces 308 of the multi-faceted ring 302 of the spoke array 300. For example, the first boss 328 can include one or more outer surfaces 332 (e.g., five outer surfaces 332 with a rounded transition 334 between adjacent ones of the five outer surfaces 332). For example, the five outer surfaces 332 of the first boss 328 can be sized and the shape of the outer periphery of the first boss 328 can be set such that, when the multi-faceted ring 302 is positioned around the first boss 328 and on the first flange 324, the five outer surfaces 332 of the first boss 328 contact (e.g., abut) the five inner surfaces 308 of the multi-faceted ring 302, respectively, for example. The first boss 328 can have any number of different heights. For example, the height of the first boss 328 can be greater than or equal to the thickness of the multi-faceted ring 302. Other sizes and / or shapes of the first boss 328 can be provided.

[0107] The size and shape of the second boss 330 (e.g., the size and shape of the outer periphery) can correspond to the size and shape defined by one or more of the inner surfaces 308 of the multi-faceted ring 302 of the spoke array 300. For example, the second boss 330 can include one or more outer surfaces 336 (e.g., five outer surfaces 336 with a rounded transition 338 between adjacent ones of the five outer surfaces 336). For example, the five outer surfaces 336 can be sized and the shape of the outer periphery of the second boss 330 can be set such that, when the multi-faceted ring 302 is positioned around the second boss 330 and on the second flange 326, the five outer surfaces 336 of the second boss 330 contact the five inner surfaces 308 of the multi-faceted ring 302, respectively, for example. The second boss 330 can have any number of different heights. For example, the height of the second boss 330 can be greater than or equal to the thickness of the multi-faceted ring 302. Other sizes and / or shapes of the second boss 330 can be provided.

[0108] The center hub 126 can include one or more first retention features 340 (e.g., first retention features 340) at the first boss 328 and / or the first flange 324. In one embodiment, the first retention features 340 are first detent features. In one embodiment, the first detent features 340 extend into the first boss 328 of the center hub 126. For example, the first detent features 340 are first grooves that extend at least partially around an outer perimeter of the first boss 328. In one embodiment, the first grooves 340 extend completely around the outer perimeter of the first boss 328 (e.g., are disposed within all of the outer surfaces of the one or more outer surfaces 332 of the first boss 328). In another embodiment, the first detent features 340 are protrusions that extend at least partially around the outer perimeter of the first boss 328 and away from the one or more outer surfaces 332 of the first boss 328.

[0109] The center hub 126 can also include one or more second retention features (e.g., second retention features; not shown) at the second boss 330 and / or the second flange 326. In one embodiment, the second retention features are second detent features. In one embodiment, the second detent features extend into the second boss 330 of the center hub 126. For example, the second detent features are second grooves that extend at least partially around an outer perimeter of the second boss 330. In one embodiment, the second grooves extend completely around the outer perimeter of the second boss 330 (e.g., are disposed within all of the outer surfaces of the one or more outer surfaces 336 of the second boss 330). In another embodiment, the second detent features are protrusions that extend at least partially around the outer perimeter of the second boss 330 and away from the one or more outer surfaces 336 of the second boss 330.

[0110] In other embodiments, the center hub 126 can include more and / or different retention features at the first boss 328 and / or the second boss 330. For example, the center hub 126 can include two or more first retention features 340 at the first boss 328 of the center hub 126 and / or can include two or more second retention features at the second boss 330 of the center hub 126. For example, the first boss 328 includes two grooves 340 spaced apart from each other within the first boss 328, and the second boss 330 includes two grooves spaced apart from each other within the second boss 330.

[0111] Referring to Figure 10 and Figure 11The multi-faceted ring 302 of the spoke array 300 includes one or more retention features 342 (e.g., a retention feature). For example, the multi-faceted ring 302 of the spoke array 300 includes a retention feature 342 at one or more inner surfaces 308 of the multi-faceted ring 302. In one embodiment, the retention feature 342 is a stop feature that extends away from the one or more inner surfaces 308 of the multi-faceted ring 302 at least partially around an inner perimeter defined by the one or more inner surfaces 308 of the multi-faceted ring 302. For example, the stop feature 342 extends completely around the inner perimeter of the multi-faceted ring 302. The stop feature 342 can be configured in any number of ways. For example, the stop feature 342 can be a protrusion or rib that extends completely around the inner perimeter of the multi-faceted ring 302.

[0112] The stop feature 342 can be sized and / or shaped in any number of ways. For example, the stop feature 342 is sized and shaped to correspond to the first retention feature 340 of the first boss 328 and / or the second retention feature of the second boss 330. In other words, one or more surfaces forming the stop feature 342 can contact one or more surfaces forming the first groove 340 of the first boss 328 or the second groove of the second boss 330, for example, when the spoke array 300 is positioned on the first boss 328 or the second boss 330 of the center hub 126.

[0113] In one embodiment, the multi-faceted ring 302 can include more and / or different retention features (e.g., at the one or more inner surfaces 308 of the multi-faceted ring 302). For example, the stop feature 342 can be a groove that corresponds to a protrusion on the first boss 328 of the center hub 126 and / or a protrusion on the second boss 330 of the center hub 126. In one embodiment, the multi-faceted ring 302 includes two or more stop features 342 at the one or more inner surfaces 308 of the multi-faceted ring 302. For example, the multi-faceted ring 302 includes two circumferential ribs 342 that are spaced apart from each other and extend away from the one or more inner surfaces 308 of the multi-faceted ring 302.

[0114] To attach the spoke array 300 to the center hub 126 (e.g., at the first end 320 or the second end 322 of the center hub 126), the multi-faceted ring 302 is disposed around the first boss 328 or the second boss 330 and the spoke array 300 is moved in the direction D (see FIG. 3A) until the one or more retention features 342 of the multi-faceted ring 302 are received within the first retention feature 340 of the first boss 328 or the second retention feature of the second boss 330. Figure 10) pushing the polygonal ring 302 downward until the polygonal ring 302 contacts the first flange 324 or the second flange 326 of the center hub 126 and the stop feature 342 (e.g., a circumferential rib) engages the first retention feature 340 or the second retention feature of the center hub 126. For example, as the polygonal ring 302 is pushed downward in the direction D toward the first flange 324 or the second flange 326 of the center hub 126, the stop feature 342 moves into the first groove 340 or the second groove of the center hub 126, and the polygonal ring 302, and thus the spoke array 300, is at least translationally locked relative to the center hub 126.

[0115] For each wheel (e.g., the front wheels 54 and the rear wheels 56), the attachment process described with reference to Figure 10 and Figure 11 may be repeated twice. For example, the spoke array 300 can be attached to the center hub 126 at each of the first side 312 and the second side 314 of the center hub 126. All four of the spoke arrays 300 (e.g., for each side 312, 314 of each of the front wheels 54, the rear wheels 56) can be constructed in the same manner. Brake rotors or axle end caps can also be used to mechanically capture the polygonal ring 302 of the spoke array 300.

[0116] In other embodiments, different subsets of the spoke arrays 300 can be constructed differently. For example, the spoke arrays 300 can be constructed for a particular side of a wheel (e.g., at or near the first end 320 or the second end 322 of the hub 126; corresponding to the first side 160 or the second side 162 of the respective front wheel 54, rear wheel 56). For example, different subsets of the spoke arrays 300 can include different stop features 342 that respectively correspond to different grooves (e.g., the first groove 340 and the second groove of the center hub 126) located at and / or adjacent to the first end 320 and the second end 322 of the center hub 126. For example, the position of the first groove 340 along the first ledge 328 relative to the first flange 324 can be different than the position of the second groove along the second ledge 330 relative to the second flange 326. In other words, the distance between the first flange 324 and the first groove 340 can be different (e.g., greater or less) than the distance between the second flange 326 and the second groove. Thus, different spoke arrays 300 can correspond to different center hubs 126, different sides of the center hub 126, and / or different wheels (e.g., the front wheels 54 or the rear wheels 56).

[0117] Other constructions can be provided. For example, the spoke arrays for different wheels (e.g., the front wheels 54 and the rear wheels 56) can be constructed differently. For example, Figures 5 to 11The spoke array 300 shown in FIG. 3 can be included within one of the front wheel (e.g., the front wheel 54) and the rear wheel (e.g., the rear wheel 56), and another spoke array can be included within the other of the front wheel and the rear wheel. For example, the other spoke array can include more, fewer, and / or different spokes integrated with the polygonal ring.

[0118] The spoke array 300 can be removably attached to the center hub 126. For example, a standard tool such as a flathead screwdriver can be used to remove the spoke array 300 from the center hub 126. A user can wedge the screwdriver or other tool (e.g., a tool) having a flat rim between the polygonal ring 302 of the spoke array 300 and the first flange 324 or the second flange 326 of the center hub 126, rotate or translate the tool to move the detent feature 342 of the spoke array 300, for example, out of a corresponding groove (e.g., the first groove 340) of the center hub 126, for example, to allow the spoke array 300 to be translated out of the center hub 126.

[0119] Referring to Figure 10 and Figure 11 The plurality of spokes 304 can be at one or more angles (e.g., the angle a) relative to the plane P defined by the polygonal ring 302 such that each spoke of the plurality of spokes 304 extends to a central portion (e.g., an innermost portion) of a spoke-receiving surface of a spoke-engaging portion of the rim (e.g., the spoke-engaging portion 204 of the rim 200). The plurality of spokes 304 can extend through the spoke-receiving surface of the rim and can be connected to the rim within the rim. The plurality of spokes 304 can be connected to the rim in any number of ways. For example, respective end portions of the plurality of spokes 304 can be threaded and the plurality of spokes 304 can be connected to the rim via the threaded end portions of the plurality of spokes 304 and a threaded joint. The plurality of spokes 304 can be connected to the rim in other ways.

[0120] The spoke array 300 can be used with (e.g., connected to) any number of different types of rims. For example, the spoke array 300 can be used with rims having protrusions configured as tire retention features, single-walled rims, double-walled rims, tubular rims, and / or other types of rims.

[0121] The polygonal ring 302 of the spoke array 300 can be shaped in any number of different ways. For example, the polygonal ring 302 (e.g., one or more inner surfaces 308 of the polygonal ring 302) of the spoke array 300 can be shaped as any number of polygons. In one embodiment, one or more inner surfaces 308 of the polygonal ring 302 form a shape having a plurality of sides that are optimized for transferring torque loads between the center hub 126 and the plurality of spokes 304 of the spoke array 300. In different embodiments, one or more inner surfaces 308 of the polygonal ring 302 can form a square, a pentagon, a hexagon, a heptagon, an octagon, another polygon, a polygon having a lobed interface, or another shape.

[0122] Figures 13 to 15 Examples of spoke arrays are shown having center flanges of different shapes. Figure 13 A spoke array 400 is shown that includes a center flange 402 (e.g., a polygonal ring) and a plurality of spokes 404 that are integral with and extend away from the polygonal ring 402. The polygonal ring 402 has, for example, six inner surfaces 406 (e.g., and circular transitions 408 between adjacent pairs of the six inner surfaces 406) that form a hexagon. In the case of this embodiment of the center flange 402, the center hub can include a first boss at a first end of the center hub and a second boss at a second end of the center hub, and outer surfaces of the first boss and the second boss can form a hexagon that is sized to match the hexagon formed by the inner surfaces of the polygonal ring 402.

[0123] Figure 14 A spoke array 500 is shown that includes a center flange 502 (e.g., a polygonal ring) and a plurality of spokes 504 that are integral with and extend away from the polygonal ring 502. The polygonal ring 502 has, for example, 24 inner surfaces 506 (e.g., and circular transitions 508 between adjacent pairs of the 24 inner surfaces 506) that form a star polygon. In the case of this embodiment of the center flange 502, the center hub can include a first boss at a first end of the center hub and a second boss at a second end of the center hub, and outer surfaces of the first boss and the second boss can form a star polygon that is sized to match the star polygon formed by the inner surfaces of the polygonal ring 502.

[0124] Figure 15A spoke array 600 is shown that includes a center flange 602 (e.g., a polygonal ring) and a plurality of spokes 604 that are integral with and extend away from the polygonal ring 602. The polygonal ring 602 has, for example, five inner surfaces 606 that form a pentagon. With this embodiment of the center flange 602, the center hub can include a first boss at a first end of the center hub and a second boss at a second end of the center hub, and an outer surface of the first boss and an outer surface of the second boss can form a pentagon that is sized to match the pentagon formed by the inner surfaces of the polygonal ring 602. The polygonal ring 602 can also include convex curved transitions 608 (e.g., lobed interfaces) between adjacent pairs of the five inner surfaces 606.

[0125] In one embodiment, a layup pattern of composite material layers for a spoke array (e.g., spoke array 300, 400, 500, or 600) is provided prior to a curing process, for example, to form the spoke array. After the curing process, the composite material layers can be part of a single-piece monolithic spoke array 300. The resulting single-piece monolithic spoke array 300 can be formed from a composite laminate that includes one or more compression layers of one or more composite materials.

[0126] Figure 16 One embodiment of a strip 700 of composite material (e.g., a first composite material) is shown. The composite material includes a matrix 702 of a polymer-based material and fibers 704 of a reinforcing material. The polymer-based material can be any number of materials including, for example, a plastic, an acrylic, a resin, an epoxy, another polymer-based material, or any combination thereof. The fibers of the reinforcing material can be carbon fibers. Other polymer-based materials and / or other reinforcing fibers can be used.

[0127] Fibers 704 extend along a finite length / of the strip 700. In one embodiment, the fibers 704 extend in a primary strength direction of the strip 700 (e.g., along the length / of the strip 700). For example, the strip 700 has a unidirectional fiber orientation along the length / . In another embodiment, some fibers (e.g., less than 20% of the fibers, less than 10% of the fibers, or less than 5% of the fibers) do not extend in the primary strength direction. The strip 700 can be any number of shapes and / or sizes. For example, the strip 700 is rectangular in shape. Other shapes can be provided, such as square strips and non-rectangular parallelogram strips. The strip 700 also includes a width w that is perpendicular to the length / . The length / can be defined in part by the length of the spokes in the plurality of spokes 304 of, for example, the spoke array. In one embodiment, the width w of the strip 700 is between 10 mm and 30 mm. For example, the width w of the strip 700 is 20 mm. In other embodiments, the strip 700 is wider or narrower. Smaller strip widths better optimize fiber orientation, but at the cost of increased manufacturing complexity.

[0128] For example, the strip 700 provides ultimate strength in the direction of the fiber grains. Thus, for example, fiber alignment along the spokes of the plurality of spokes 304 can be provided. For example, Figures 17A to 17D Examples of continuous fiber paths within the spoke array 300 are shown. In Figures 17A to 17D In the example of FIG. 8A, the plurality of spokes 304 includes, for example, ten spokes 304a-304j. In Figure 17A In a first example of FIG. 8A, the continuous fiber path 800 forms a first spoke 304a and a sixth spoke 304f of the plurality of spokes 304. The first spoke 304a and the sixth spoke 304f are at an obtuse angle (e.g., 160 degrees or 165 degrees) relative to each other. The continuous fiber path 800 forms a portion of the multi-sided ring 302 (e.g., at least a portion of one side of the multi-sided ring 302). The continuous fiber path 800 is repeated four additional times to form the remaining spokes (e.g., second spoke 304b, third spoke 304c, fourth spoke 304d, fifth spoke 304e, seventh spoke 304g, eighth spoke 304h, ninth spoke 304i, and tenth spoke 304j) of the plurality of spokes 304 and the remaining portion of the multi-sided ring 302.

[0129] In Figure 17B In a second example of FIG. 8B, the continuous fiber path 802 forms a first spoke 304a and an eighth spoke 304h of the plurality of spokes 304. The first spoke 304a and the eighth spoke 304h are at an obtuse angle (e.g., 100 degrees or 115 degrees) relative to each other. Figure 17B The obtuse angle shown by the continuous fiber path 802 of Figure 17Aobtuse angle shown by the continuous fiber path 800 of FIG. 8A. The continuous fiber path 802 forms a portion of the polygonal ring 302 (e.g., at least a portion of two sides of the polygonal ring 302). The continuous fiber path 802 is repeated four more times to form the remaining spokes (e.g., the second spoke 304b, the third spoke 304c, the fourth spoke 304d, the fifth spoke 304e, the sixth spoke 304f, the seventh spoke 304g, the ninth spoke 304i, and the tenth spoke 304j) of the plurality of spokes 304 and the remaining portion of the polygonal ring 302.

[0130] In a third example of the first embodiment, the continuous fiber path 804 forms the first spoke 304a and the tenth spoke 304j of the plurality of spokes 304. The first spoke 304a and the tenth spoke 304j are at an acute angle (e.g., 35 degrees or 40 degrees) relative to each other. Figure 17C In a fourth example of the first embodiment, the continuous fiber path 806 forms the first spoke 304a and the second spoke 304b of the plurality of spokes 304. The first spoke 304a and the second spoke 304b are at an acute angle (e.g., 40 degrees or 45 degrees) relative to each other.

[0131] Figure 17D In a fourth example of the first embodiment, the continuous fiber path 806 forms the first spoke 304a and the second spoke 304b of the plurality of spokes 304. The first spoke 304a and the second spoke 304b are at an acute angle (e.g., 40 degrees or 45 degrees) relative to each other. Figure 17D The acute angle shown by the continuous fiber path 806 of the first embodiment can be less than, equal to, or greater than the acute angle shown by the continuous fiber path 804 of the first embodiment. The continuous fiber path 806 forms a portion of the polygonal ring 302 (e.g., at least a portion of four sides of the polygonal ring 302). The continuous fiber path 806 is repeated four more times to form the remaining spokes (e.g., the third spoke 304c, the fourth spoke 304d, the fifth spoke 304e, the sixth spoke 304f, the seventh spoke 304g, the eighth spoke 304h, the ninth spoke 304i, and the tenth spoke 304j) of the plurality of spokes 304 and the remaining portion of the polygonal ring 302. In other embodiments, other continuous fiber paths can be provided. Figure 17C

[0132] Figure 18 ​​A method 900 for manufacturing a bicycle component (e.g., a spoke array 300) of a bicycle (e.g., bicycle 50) is shown. The acts of method 900 presented below are intended to be illustrative. In some embodiments, method 900 can be completed with one or more additional acts not described, and / or without one or more of the acts described. Additionally, the order in which the acts of method 900 are presented in Figure 18 is not intended to be limiting.

[0133] In act 902, at least one layer (e.g., one layer) of a first composite material is positioned within a mold. The first composite material includes a matrix of a first polymeric base material and fibers of a first reinforcement material. In one embodiment, the fiber orientation of the fibers of the first reinforcement material of the layer of the first composite material is unidirectional in a direction along a length of the respective layer.

[0134] The layer of the first composite material can be any number of shapes and / or sizes. For example, the shape of the layer of the first composite material can be rectangular and can have a length that is at least twice a length of a spoke of a wheel to be manufactured. Other shapes and / or sizes can be provided.

[0135] The first polymeric base material can be or include any number of polymeric base materials including, for example, a thermoplastic matrix, a thermoset matrix, or a combination thereof. The fibers of the first reinforcement material can be or include any number of different types of fibers including, for example, carbon fibers, glass fibers, flax fibers, kenaf fibers, hemp fibers, jute fibers, sisal fibers, or any combination thereof. Other polymeric base materials and / or other reinforcement materials can be used for the first composite material.

[0136] In one embodiment, the layer of the first composite material is positioned within the mold such that the layer of the first composite material forms at least a portion of a spoke and a center flange (e.g., a polygonal ring) of a spoke array to be manufactured. In other embodiments, the layer of the first composite material is positioned within the mold such that the layer of the first composite material forms at least a portion of another portion (e.g., another spoke of the spoke array) of the spoke array to be manufactured.

[0137] In act 904, at least one layer (e.g., one layer) of a second composite material is positioned within the mold such that the layer of the second composite material abuts and / or overlaps (e.g., within the polygonal ring) the layer of the first composite material. The second composite material includes a matrix of a second polymeric base material and fibers of a second reinforcement material. The second polymeric base material can be the same as or different from the first polymeric base material, and / or the second reinforcement material can be the same as or different from the first reinforcement material.

[0138] The second polymer-based material can be or include any number of polymer-based materials including, for example, plastic, acrylic, resin, epoxy, or any combination thereof. The fibers of the second reinforcement material can be or include any number of different types of fibers including, for example, carbon fiber, glass fiber, flax fiber, kenaf fiber, hemp fiber, jute fiber, sisal fiber, or any combination thereof. Other polymer-based materials and / or other reinforcement materials can be used for the second composite material.

[0139] The layer of the second composite material can be any number of shapes and / or sizes. For example, the layer of the second composite material can be rectangular in shape and can have a length that is at least twice the length of the spokes of the spoke array to be manufactured. Other shapes and / or sizes can be provided. In one embodiment, the layer of the second composite material is longer than the layer of the first composite material. In another embodiment, the layer of the second composite material has the same size (e.g., length) as the layer of the first composite material.

[0140] In one embodiment, the layer of the second composite material is positioned within the mold such that the layer of the second composite material forms at least a portion of the spokes of the spoke array to be manufactured and the polygonal ring. In other embodiments, the layer of the second composite material is positioned within the mold such that the layer of the second composite material forms at least a portion of another portion (e.g., another spoke) of the spoke array to be manufactured.

[0141] Actions 902 and / or 904 can be repeated any number of times to form the stacked pattern of the bicycle component. In one embodiment, actions 902 and / or 904 can be repeated with one or more additional actions in which one or more other layers of composite material are positioned any number of times to, for example, form the stacked pattern. For example, the second composite material can be the same as the first composite material and action 904 can be repeated three more times such that the stacked pattern is for ten spokes.

[0142] In action 906, the bicycle component is formed. Forming the bicycle component includes forming a composite laminate (e.g., laminate) that includes at least the layer of the first composite material and the layer of the second composite material within the mold. In one embodiment, forming the bicycle component includes forming a composite laminate that includes at least the layer of the first composite material, the layer of the second composite material, and a layer of a third composite material (e.g., the same as or different from the first and / or second composite materials) within the mold.

[0143] The mold can be used to form all or a portion of a bicycle component. For example, for a spoke array, the mold can be broken down into multiple pieces to allow access to the mold when positioning the layer of at least the first material in act 902 and positioning the layer of the second material in act 904. For example, the mold can be broken down into multiple radial portions (e.g., two radial portions) and / or multiple pieces (e.g., a top piece and a bottom piece).

[0144] Forming the composite laminate can include shaping and curing the composite laminate, e.g., within a mold. For example, a layer of at least a first composite material and a layer of a second composite material can be positioned within a mold, and the layer of the first composite material and the layer of the second composite material can be shaped using a bladder that is inflated within the mold. The composite laminate can be shaped in other ways.

[0145] Once shaped, the composite laminate can be cured in any number of ways, including, for example, by pressing, autoclave curing, or oven curing the composite laminate including at least the layer of the first composite material and the layer of the second composite material. Other types of curing can be used.

[0146] The illustrations of the embodiments described herein are intended to provide a general understanding of the structure of various embodiments. The illustrations are not intended to serve as a complete description of all of the elements and features of apparatus and systems that utilize the structures or methods described herein. Many other embodiments can be apparent to those of ordinary skill in the art upon reviewing this disclosure. Other embodiments can be utilized and derived from the disclosure, such that structural and logical substitutions and changes can be made without departing from the scope of the disclosure. Additionally, the illustrations are merely representative and can not be drawn to scale. Certain proportions within the illustrations can be exaggerated, while other proportions can be minimized. Accordingly, the disclosure and the figures are to be regarded as illustrative in nature and not as restrictive.

[0147] While this specification contains many details, these should not be construed as limitations on the scope of that which is described, but as descriptions of features that can be specific to particular embodiments. Certain features that are described in the context of separate embodiments can also be implemented in combination with each other. Conversely, various features that are described in the context of a single embodiment can also be implemented or practiced separately or in any suitable subcombination. Moreover, although features can be described above as acting in certain combinations and even initially claimed as such, one or more features from a claimed combination can in some cases be excised from the combination and the claimed combination can be directed to a subcombination or variation of a subcombination.

[0148] Similarly, while operations and / or actions are depicted in the drawings and described herein in a particular order, this should not be understood as requiring such order nor as requiring that all illustrated operations be performed to achieve desirable results. Further, the drawings and text can depict only one or a handful of embodiments of a process, system, article of manufacture, etc. and are therefore not intended to limit the scope of the disclosure to only these illustrated embodiments.

[0149] One or more embodiments of the present disclosure can be referred to herein, individually and / or collectively, by the term “invention” merely for convenience and are not intended to voluntarily limit the scope of this application to any particular invention or inventive concept. Moreover, although specific embodiments have been shown and described herein, it is understood that any subsequent arrangement designed to achieve the same or similar purpose will be fall within the scope of the appended claims. The present disclosure is intended to cover any and all subsequent adaptations or variations of various embodiments. Combinations of the above embodiments, and other embodiments not specifically described herein, will be apparent to those of reasonable skill in the art upon reading the description.

[0150] The Abstract of the Disclosure is provided to comply with 37 C.F.R. § 1.72 and is submitted to the Patent and Trademark Office (PTO) and does not necessarily reflect the content of the full disclosure, and is not intended to limit the scope thereof in any way. Additionally, in the preceding detailed description, various features are grouped together in examples for the purpose of streamlining the disclosure. This disclosure is not to be interpreted to be limited to the embodiments illustrated in the examples. The present disclosure is intended to encompass any and all subsequent adaptations or variations of various embodiments. Combinations of the above embodiments, and other embodiments not specifically described herein, will be apparent to those of reasonable skill in the art upon reading the description.

[0151] The foregoing detailed description has been stated in terms of specific embodiments for the purpose of the proper understanding of the disclosure. It will be understood that the following claims are intended to include all embodiments falling within the scope of the claims. The claims should not be understood to be limited to the described order or elements unless such is stated in the claims. Therefore, all embodiments falling within the scope of the following claims and their equivalents are intended to be claimed.

[0152] This application claims the benefit of U.S. Provisional Patent Application No. 63 / 647,747, filed May 15, 2024, which is incorporated by reference herein in its entirety.

Claims

1. A wheel for a bicycle, the wheel comprising: A center hub having a first end and a second end opposite to the first end, wherein the center hub is configured for rotatably attaching to the bicycle; A rim, the rim including a radially inner portion disposed along the inner circumference of the rim; A first spoke array, removably attached to the radially inner portion of the center hub and the rim, the first spoke array being located on a first side of the wheel and comprising: First central flange; and A plurality of first spokes, said plurality of first spokes being integral with and extending away from the first central flange, thereby forming a first single part; and A second spoke array, removably attached to the radially inner portion of the center hub and the rim, the second spoke array being located on a second side of the wheel opposite to a first side of the wheel, the second spoke array comprising: Second central flange; and A plurality of second spokes, which are integral with and extend away from the second central flange, thereby forming a second single part.

2. The wheel according to claim 1, wherein, The center hub includes a first flange and a second flange. The first flange is closer to the first end of the center hub than the second end, and the second flange is closer to the second end of the center hub than the first end. The first spoke array is removably attached to the first flange of the center hub, and the second spoke array is removably attached to the second flange of the center hub.

3. The wheel according to claim 1, wherein, The first central flange and a plurality of first spokes of the first spoke array are made of a first material, and the second central flange and a plurality of second spokes of the second spoke array are made of a second material.

4. The wheel according to claim 3, wherein, The first material and the second material are the same carbon fiber composite material.

5. The wheel according to claim 3, wherein, The rim also includes: First sidewall; A second sidewall spaced apart from the first sidewall, wherein the first and second sidewalls extend radially outward from the radially inner portion; and A radially outer tire engagement portion, the radially outer tire engagement portion being disposed along the outer circumference of the rim, the radially outer tire engagement portion extending from the first sidewall and the second sidewall respectively, and The first sidewall, the second sidewall, the radially outer tire engagement portion, and the radially inner portion of the rim are made of a third material, which is a carbon fiber composite material.

6. The wheel according to claim 2, wherein, The first central flange is a first polyhedral ring, and the second central flange is a second polyhedral ring.

7. The wheel according to claim 6, wherein, Each of the first polyhedral ring and the second polyhedral ring has an inner surface shaped as a square, pentagon, hexagon, heptagon, or octagon.

8. The wheel according to claim 7, wherein, The center hub further includes a first boss extending between the first flange and the first end, and a second boss extending between the second flange and the second end. The outer surface of the first boss has the same shape as the inner surface of the first multifaceted ring, and the outer surface of the second boss has the same shape as the inner surface of the second multifaceted ring.

9. The wheel according to claim 8, wherein, The first boss includes a first retaining feature on its outer surface, and the first multifaceted ring includes a second retaining feature on its inner surface, the second retaining feature being configured to interact with the first retaining feature such that the first spoke array is attached to the center hub. The second boss includes a third retaining feature on the outer surface of the second boss, and the second multifaceted ring includes a fourth retaining feature on the inner surface of the second multifaceted ring, the fourth retaining feature being configured to interact with the third retaining feature such that the second spoke array is attached to the center hub.

10. The wheel according to claim 9, wherein, The first retaining feature is a first stop extending into the first boss, and the second retaining feature is a second stop extending away from the inner surface of the first faceted ring. The third retaining feature is a third stop extending into the second boss, and the fourth retaining feature is a fourth stop extending away from the inner surface of the second multifaceted ring.

11. The wheel according to claim 1, further comprising a spoke interface structure, the spoke interface structure including a spoke joint, a spoke joining structure, and a tension adjusting element. in, The tension adjustment element is located inside the rim, above the spoke joint.

12. A spoke array removably attached to a center hub and rim of a bicycle wheel, such that the spoke array forms all the spokes on one side of the wheel, the spoke array comprising: Central flange; and Multiple spokes, which are integral with the central flange and extend away from the central flange, thereby forming a single part.

13. The spoke array according to claim 12, wherein, The central flange and the plurality of spokes integral with the central flange are made of carbon fiber composite material, and The carbon fiber composite material comprises a polymer matrix and reinforcing fibers, wherein the reinforcing fibers are carbon fibers.

14. The spoke array according to claim 13, wherein, The continuous fibers of the carbon fiber extend from the first spoke of the plurality of spokes via the central flange to the second spoke of the plurality of spokes.

15. The spoke array according to claim 14, wherein, The first spoke is at an angle relative to the second spoke.

16. The spoke array according to claim 15, wherein, The angle mentioned is an acute angle.

17. The spoke array according to claim 12, wherein, The central flange is a multifaceted ring, which has an inner surface shaped as a square, pentagon, hexagon, heptagon, or octagon.

18. The spoke array according to claim 12, wherein, The multifaceted ring includes a retaining feature on the inner surface of the multifaceted ring.

19. The spoke array according to claim 18, wherein, The retaining feature is a protrusion extending radially inward from the inner surface of the multifaceted ring.

20. The spoke array according to claim 19, wherein, The protrusion is a circumferential rib extending around the inner surface of the multifaceted ring.

Images