The process of manufacturing spoked bicycle wheels and related wheels

Abstract

The present invention relates to a process aimed at manufacturing a spoke bicycle wheel and to the related wheel, the process comprising the steps of: a) providing a rim element having spoke attachment chambers, the chambers being provided with openings and spoke attachment surfaces comprising spoke attachment seats; b) providing spoke attachment assemblies comprising a joint having an enlarged head and a stem, the stem being provided with a coupling portion configured to be coupled to a corresponding spoke, and a shaped washer, the washer being applied to the stem; c) inserting the assembly into the chamber through the opening along an insertion direction inclined with respect to a horizontal plane arranged under the rim element and according to an insertion sense oriented away from the horizontal plane; d) moving the spoke attachment assembly along the insertion direction until bringing the stem at the spoke attachment surface; e) moving the assembly along the spoke attachment surface and up to one spoke attachment seat; f) inserting the stem into the spoke attachment seat; g) constraining the assembly to the spoke attachment seat; h) repeating steps c) to g) to couple a corresponding spoke attachment assembly to each spoke attachment seat.

Description

Technical Field

[0001] The present invention relates to a process for manufacturing spoked bicycle wheels and a spoked bicycle wheel that can be obtained by performing the aforementioned process. Background Technology

[0002] The aforementioned wheel can be either the front or rear wheel of a bicycle. This type of bicycle can be a mountain bike, a recreational bike, or a racing bike.

[0003] A spoked bicycle wheel consists of a rim, a hub, and multiple spokes extending between the hub and the rim.

[0004] It is known that the rim is connected to multiple joints (one for each spoke); and each spoke is connected to the rim via the corresponding joint.

[0005] A joint can be configured to allow adjustment of the spoke tension at the rim. In contrast, a joint can simply allow connection between the spokes and the rim. In this case, the spoke tension can be adjusted at the hub.

[0006] The joint includes an enlarged head and a post, the enlarged head being configured to abut against the rim when the spokes are tensioned, and the post having a connecting portion configured to connect to the spokes.

[0007] When the joint is configured to allow adjustment of the spoke tension, the connection includes a threaded hole open at the free end of the post.

[0008] The spokes include: an end configured to be conventionally attached to the hub; and an opposite end configured to be attached to the rim.

[0009] When the joint is configured to allow adjustment of spoke tension, the aforementioned opposite ends of the spoke have external threads configured to screw into the threaded hole of the corresponding joint. The length of the aforementioned external thread can be equal to the length of the threaded hole of the joint, but the length of the aforementioned external thread is generally greater than the length of the threaded hole of the joint, such that the spoke tension can be adjusted by screwing the spoke into or out of the joint. This screwing in / out is achieved by rotating the joint. Due to this screwing in / out, the depth of the spoke screwed into the threaded hole of the joint changes, and therefore, the total longitudinal extension length of the assembly formed by the spoke and the joint increases or decreases.

[0010] The following definitions apply throughout this specification and claims.

[0011] The terms “axial,” “axially,” and similar terms are used to refer to a direction that is approximately coincident with or parallel to the axis of rotation of a wheel.

[0012] The terms “radial,” “radially,” and similar terms are used to refer to a direction that is perpendicular to the axis of rotation of the wheel and incident on the axis of rotation of the wheel.

[0013] The terms “circumferential,” “circumferentially,” and similar terms are used to refer to the orientation of a line extending along the axis of rotation of a wheel.

[0014] The terms “axial interior” and “axial exterior” and similar terms are used to refer to positions closer to and farther from the lateral midplane of the wheel, respectively, while the terms “radial interior” and “radial exterior” and similar terms are used to refer to positions closer to and farther from the axis of rotation of the wheel, respectively.

[0015] On the other hand, the term "longitudinal" is used to refer to the main direction of extension of the bicycle component under consideration.

[0016] The term "composite material" is used to refer to a material comprising structural fibers incorporated within a polymer material. The structural fibers are preferably selected from the group consisting of carbon fibers, glass fibers, boron fibers, aramid fibers, ceramic fibers, and combinations thereof. The polymer material can be thermoplastic or thermosetting.

[0017] Rim with radially external tire coupling channels and radially internal spoke attachment chambers is known. For example, this type of rim is shown in US2007 / 0158996A1, filed by the same applicant.

[0018] Typically, rims are made of aluminum or its alloys (in which case they can be obtained by extrusion of forming rods) or of composite materials (in which case they can be obtained by injection or compression molding).

[0019] The spoke attachment chamber includes a lower bridge with a plurality of spoke attachment through holes formed therein, each spoke attachment through hole being configured to receive a corresponding joint, and a through hole is also formed in the lower bridge for passage of the inflation valve of the tire chamber of the wheel, or, in the case of a tubeless tire, for passage of the inflation valve of the tire itself.

[0020] The spoke attachment chamber further includes an upper bridging member in which a through-hole is formed for the passage of the aforementioned inflation valve. In many solutions, additional through-holes are formed on the upper bridging member, with an additional through-hole at each spoke attachment through-hole to allow the connector to be inserted into the corresponding spoke attachment through-hole.

[0021] Each joint's post is inserted radially outward from the lower bridge member relative to the rim into the corresponding spoke attachment through hole, while the joint's enlarged head remains radially outward relative to the lower bridge member and abuts against the lower bridge member after the spokes have been attached to the joint (usually screwed into the joint's threaded hole) and tensioned.

[0022] When the rim is made of aluminum (or its alloy), the enlarged head of the joint typically abuts against a suitable abutment seat, which is formed in the lower bridging member of the rim in a recess (which is typically made by mechanical chip removal) formed at least at each spoke attachment through-hole.

[0023] When the rim is made of a composite material, the aforementioned recess is difficult to fabricate due to the processing difficulties of the composite material. Therefore, the enlarged head of the joint typically abuts against a perforated insert specially arranged on the lower bridging member of the rim at each spoke attachment through-hole. The perforated insert is usually co-molded with the rim, as described, for example, in the same applicant's EP3495161A1, and can be made, for example, of polyetherimide, which is commercialized by Sabic of Riyadh under the trade name Ultem 2400.

[0024] The disadvantage of the last solution, due to the specific materials used, is the cost of the perforated insert.

[0025] Similarly, when the rim is made of composite material, a more cost-effective solution is known to use multiple shaped washers made of steel instead of the aforementioned perforated inserts, each shaped washer positioned at each spoke attachment through-hole. In this case, the lower bridge has a generally flat circumferential surface on which the aforementioned shaped washer rests. On the other hand, the upper bridge has multiple maintenance holes, one at each spoke attachment through-hole, to allow the shaped washer and corresponding connector to be inserted into the spoke attachment chamber and positioned at the corresponding spoke attachment through-hole using, for example, a suitable slender tool.

[0026] The drawback of this solution is that it requires applying a strip to the upper bridge connector to seal the aforementioned service hole, thus eliminating the risk of damaging or puncturing the tire's air chamber while allowing for an airtight seal when using a rim configured for use with tubeless tires.

[0027] A solution to the problem of providing multiple service holes on the upper bridge of a rim is described in US2007 / 0158996A1 by the same applicant. This document discloses a rim in which the upper bridge has only one through-hole or a limited number of service holes for a tire inflation valve. The document also describes a process intended for manufacturing a spoked bicycle wheel. This process includes the steps of inserting a connector into a spoke attachment chamber through an opening (which may be a through-hole for a tire inflation valve or a specially manufactured different opening) and guiding the connector along the spoke attachment chamber toward and to the corresponding spoke attachment seat. The process further includes the step of inserting the post of the connector into the spoke attachment seat until the head of the connector abuts against the lower bridge of the rim.

[0028] The connector described in US2007 / 0158996A1 is made of aluminum and, during the aforementioned process, is coupled to a corresponding insert made of a ferromagnetic material. Each ferromagnetic insert has a head and a threaded post that screws into a threaded hole in the connector. In this way, once the assembly of the connector and the ferromagnetic insert is inserted into the spoke attachment chamber, it is guided and moved along the spoke attachment chamber by magnetic attraction, which is applied, for example, manually or automatically, along the rim and outside the rim until a predetermined spoke attachment seat is reached. Once such a spoke attachment seat is reached, the post of the connector is removed from the spoke attachment seat due to the magnetic connection between one end of the magnet and the head of the ferromagnetic insert. Thereafter, the magnet is removed from the ferromagnetic insert, the ferromagnetic insert is screwed out of the threaded hole of the connector, and the threaded end of the spoke is screwed onto the connector.

[0029] The aforementioned process can be used for rims made of steel, aluminum (or its alloys), magnesium (or its alloys) or composite materials.

[0030] The applicant has focused its attention on rims of the type described in US2007 / 0158996A1, or rims that do not require maintenance holes to be made at each spoke attachment on the upper bridge and thus apply a band to the upper bridge in order to allow the rim to be used with tubeless tires or to avoid damage to the tire’s air chamber.

[0031] The applicant has observed that in cases where the aforementioned molded washers are used to maintain the cost-effectiveness of the rim, the process described in US2007 / 0158996A1 cannot be directly applied. Indeed, there is a risk that once these molded washers are inserted into the spoke attachment chambers, they may become scattered within such chambers, or, if inserted, have already been applied to the joint post, potentially slipping off the joint, thus complicating wheel assembly and / or manufacturing operations. Summary of the Invention

[0032] The technical problem based on this invention is to provide a system that allows easy positioning of the joint and corresponding shaped gasket at the spoke attachment of the lower bridging member of the rim in cases where the upper bridging member of the rim does not have a maintenance hole at each spoke attachment.

[0033] The present invention therefore relates in its first aspect to a process for manufacturing a spoked bicycle wheel, comprising the following steps:

[0034] a) Provide a rim element having a tire connection channel and at least one spoke attachment chamber, the at least one spoke attachment chamber having at least one opening and a spoke attachment surface, the spoke attachment surface including a plurality of spoke attachment seats;

[0035] b) Provide a spoke attachment assembly, the spoke attachment assembly comprising:

[0036] - A connector having an enlarged head and a post, the post having a connecting portion configured to be connected to a corresponding spoke;

[0037] - At least one shaped washer, said at least one shaped washer being applied to the post of the joint;

[0038] c) Insert the spoke attachment assembly into the at least one spoke attachment chamber through the at least one opening along an insertion direction inclined relative to the horizontal plane arranged below the rim element, and according to the insertion sensation oriented away from the horizontal plane;

[0039] d) Move the spoke attachment assembly along the insertion direction until the post of the connector is brought to the spoke attachment surface;

[0040] e) Move the spoke attachment assembly along the spoke attachment surface toward and until one of the spoke attachment seats;

[0041] f) Insert the post of the joint of the spoke attachment assembly into the spoke attachment seat;

[0042] g) Constrain the spoke attachment assembly to the spoke attachment seat;

[0043] h) Repeat steps c) to g) to attach the respective spoke attachment assembly to each of the plurality of spoke attachment seats.

[0044] In a second aspect, the present invention relates to a process for manufacturing a spoked bicycle wheel, comprising the following steps:

[0045] a1) Provides a rim element having a tire connection channel and at least one spoke attachment chamber, the at least one spoke attachment chamber having at least one opening and a spoke attachment surface, the spoke attachment surface including a plurality of spoke attachment seats;

[0046] b1) Provide a spoke attachment assembly, the spoke attachment assembly comprising:

[0047] - A connector having an enlarged head and a post, the post having a connecting portion configured to be connected to a corresponding spoke;

[0048] - At least one shaped washer, said at least one shaped washer being applied to the post of the joint;

[0049] c1) The spoke attachment assembly is arranged in an operable position in which the enlarged head of the joint is positioned to hold the at least one shaped washer applied to the post of the joint.

[0050] d1) Insert the spoke attachment assembly into the at least one spoke attachment chamber through the at least one opening and along the insertion direction, thereby holding the spoke attachment assembly in the operable position;

[0051] e1) Move the spoke attachment assembly along the insertion direction until the post of the connector is brought to the spoke attachment surface;

[0052] f1) Move the spoke attachment assembly along the spoke attachment surface toward and until a spoke attachment seat is reached;

[0053] g1) Insert the post of the joint of the spoke attachment assembly into the spoke attachment seat;

[0054] h1) Constrain the spoke attachment assembly to the spoke attachment seat;

[0055] i1) Repeat steps b1) to h1) to attach each of the plurality of spoke attachments to the corresponding spoke attachment assembly.

[0056] In both of the aforementioned aspects, the movement of the spoke attachment assembly toward and up to the corresponding spoke attachment seat is achieved by the relative movement of the spoke attachment assembly relative to the rim element. Such relative movement can be achieved by moving the spoke attachment assembly without moving the rim element, or by moving (rotating) the rim element without moving the spoke attachment assembly, or by a combination of the two aforementioned movements.

[0057] In both of the aforementioned aspects, rim elements can be obtained by molding composite materials.

[0058] Alternatively, the rim element can be a shaped rod made of aluminum (or its alloy) or magnesium (or its alloy) and typically obtained through an extrusion step.

[0059] In this case, during actuation of part or all of the process according to the invention, the rim element may still be in a straight state, or may already be rim-shaped, still open at its ends or already closed. Forming into a circle can typically be done via a calendaring step. The ends can typically be joined by welding (e.g., flash welding or TIG welding), by inserting sleeves and gluing, or by pin connection or other means.

[0060] Throughout this specification and claims, the term "horizontal plane" is used to refer to a plane perpendicular to the gravity vector.

[0061] The terms “low,” “high,” “below,” and “above” are used to refer to relative positions with respect to a horizontal reference plane. Thus, for example, a “low” position relative to the ground is a position closer to the ground relative to a “high” position, while a position “below” any element is a position closer to the ground relative to a position “above” that element.

[0062] The term "insertion direction" is used to indicate the straight line along which the spoke attachment assembly moves during its insertion into the spoke attachment chamber.

[0063] The term "direction of inclination" relative to a plane is used to indicate a direction that is not parallel to that plane.

[0064] The term "insertion sensation" is used to describe the sensation of the spoke attachment assembly moving along the aforementioned insertion direction during its insertion into the spoke attachment chamber.

[0065] In the process of this invention, before the spoke attachment assembly is inserted into at least one opening of the spoke attachment chamber, at least one shaped washer is applied to the post of the joint, and this at least one shaped washer remains associated with the joint during the aforementioned insertion and until the spoke attachment assembly is constrained to the corresponding spoke attachment seat. This is due to the fact that the aforementioned insertion is along the insertion direction and based on the insertion sensation, which is oriented such that the spoke attachment assembly is arranged in an operable position in which gravity acting on the at least one shaped washer tends to move the at least one shaped washer toward the enlarged head of the joint. This operable position is maintained during the insertion of the spoke attachment assembly into the aforementioned at least one opening until the post of the joint reaches the spoke attachment surface. In this way, the assembly and / or manufacturing operations of the wheel are greatly simplified.

[0066] In a third aspect, the present invention relates to a spoked bicycle wheel, the spoked bicycle wheel comprising:

[0067] - A rim, the rim including a tire connection channel and at least one spoke attachment chamber, the at least one spoke attachment chamber having at least one opening and having a plurality of spoke attachment seats arranged on a spoke attachment surface, the at least one opening including a number of openings less than the number of spoke attachment seats;

[0068] - Multiple joints, each joint having an enlarged head and a post, the enlarged head being arranged in the at least one spoke attachment chamber, the post being inserted into a corresponding spoke attachment seat, and the post having a connecting portion configured to be connected to the corresponding spoke;

[0069] - Multiple spokes, one end of each spoke being connected to the connecting portion of the post of the corresponding joint;

[0070] The characteristic feature is that, for each of the joints, the spoked bicycle wheel includes at least one shaped washer associated with the joint and located between the enlarged head of the joint and the spoke attachment seat.

[0071] Thanks to the process of the present invention as described above, such wheels can be easily manufactured. Providing a number of openings in the at least one spoke attachment chamber, fewer than the number of spoke attachment seats, makes it possible to assemble and / or manufacture wheels with tubeless tires without applying a belt to the rim, or to avoid damaging the tire's air chamber.

[0072] In at least one of the foregoing aspects, unless otherwise expressly stated, the invention may have, alone or in combination, the preferred features described below.

[0073] One or more shaped washers may be associated with each joint, for example, two shaped washers with each joint. In the latter case, the shaped washers are arranged approximately concentrically with each other to allow for better alignment between the joint and the spokes mounted therein, especially in the case of wheels with spokes that do not have radially arranged spokes.

[0074] In the following text, for the sake of simplicity, the shaped gaskets associated with the joint will be frequently referred to. However, the same applies to situations where multiple shaped gaskets are associated with the joint, unless otherwise explicitly stated.

[0075] Preferably, the step of inserting the spoke attachment assembly into the at least one spoke attachment chamber includes associating the spoke attachment assembly with an actuation device configured to move the spoke attachment assembly toward the spoke attachment surface.

[0076] Preferably, the spoke attachment assembly further includes a portion made of a magnetically attractive material (such as steel and / or its alloys).

[0077] More preferably, such a portion made of a magnetically attractive material is defined in or by the connector, and / or is defined in or by the at least one molded washer, and / or is defined in or by another element associated with or by the connector and / or the at least one molded washer.

[0078] In this case, preferably, the actuation device is magnetic. More preferably, the actuation device includes an actuation magnet configured to be operated by an operator near the spoke attachment assembly to interact with a portion of the spoke attachment assembly made of a magnetically attractive material in order to insert the spoke attachment assembly into the spoke attachment chamber.

[0079] Preferably, the portion made of a magnetically attractive material is defined by an insert made of a metallic material.

[0080] Advantageously, once associated with the connector, the insert allows the connector to be attracted by the aforementioned manipulating magnet. This is particularly useful in the wheel manufacturing process, as will be better described below.

[0081] Preferably, the insert has a head and a threaded rod that is screwed into a threaded hole formed in the post of the connector.

[0082] Advantageously, a particularly simple insert similar to a conventional screw can be used.

[0083] Preferably, the step of inserting the spoke attachment assembly into the at least one spoke attachment chamber includes the following steps:

[0084] - The actuating magnet is attached to the spoke attachment assembly due to the magnetic interaction between the actuating magnet and the portion made of a magnetically attractive material;

[0085] - The manipulating magnet is inserted into the at least one spoke attachment chamber through the at least one opening;

[0086] - The manipulating magnet is removed from the at least one spoke attachment chamber through a second opening that is substantially aligned with the at least one opening;

[0087] - Disconnect the control magnet from the spoke attachment assembly.

[0088] Preferably, prior to the step of moving the spoke attachment assembly, the steps are as follows: maintaining the spoke attachment assembly in contact with the spoke attachment surface by disengaging the operating magnet from the spoke attachment assembly and simultaneously magnetically attaching the spoke attachment assembly to the guide magnet, with the guide magnet facing the rim element near the second opening.

[0089] Preferably, the step of moving the spoke attachment assembly is performed due to the magnetic interaction between the portion made of a magnetically attractive material and the guide magnet, and includes moving the guide magnet along the rim element toward and until one of the spoke attachment seats.

[0090] Preferably, the step of inserting the post of the connector into the spoke attachment is performed due to the magnetic connection between the guide magnet and the portion made of a magnetically attractive material.

[0091] Preferably, the portion made of a magnetically attractive material, once removably attached to the connector, is defined by the aforementioned insert made of a magnetically attractive material.

[0092] Preferably, the step of inserting the post of the connector into the spoke attachment seat includes: abutting the at least one shaped washer against the spoke attachment surface and abutting the enlarged head of the connector against the at least one shaped washer.

[0093] Preferably, the step of constraining the spoke attachment assembly to the spoke attachment seat includes connecting the post of the joint to an anchoring element configured to attach the joint to the spoke attachment seat.

[0094] The process of the present invention can be used to constrain the spoke attachment assembly in the corresponding spoke attachment seat of the rim element (which is in the form of a shaped rod still to be shaped into a circle or in the form of a shaped rod already shaped into a circle) or to manufacture the wheel of the present invention.

[0095] In cases where the operation of constraining each spoke attachment assembly to the corresponding spoke attachment seat is not performed simultaneously with wheel manufacturing—that is, before each joint is attached to the corresponding spoke, and after the insert (if provided) is removed from the joint, an anchoring element is attached to the portion of the post of the joint that protrudes from the spoke attachment surface on the opposite side to the side where the enlarged head of the joint is located. The anchoring element is larger than the size of the spoke attachment seat. Such anchoring elements are then removed during the wheel manufacturing process to associate the corresponding spoke with the joint. The aforementioned anchoring element may be, for example, an elastic ring or clamp arranged around the post of the joint or around the rod of the aforementioned insert (if provided); or the head of the aforementioned insert, which is larger than the size of the spoke attachment seat.

[0096] On the other hand, if the operation of constraining each spoke attachment assembly to the corresponding spoke attachment seat is performed during the manufacture of the wheel, step g) of constraining the spoke attachment assembly to the spoke attachment seat includes fixing the end of the spoke to the connecting portion of the post of the joint.

[0097] In a preferred embodiment, the connecting portion of the joint post includes a threaded hole that opens at the free end of the post. In this case, the spokes include external threads at their ends, which are configured to screw into the threaded hole of the joint post to allow adjustment of the spoke tension by rotating the joint.

[0098] Preferably, in the case where the spoke attachment assembly includes two molded washers, in the wheel of the present invention, the first molded washer is located between the enlarged head of the joint and the spoke attachment seat, and the second molded washer is located between the enlarged head of the joint and the first molded washer.

[0099] Preferably, the at least one opening comprises a single opening.

[0100] Preferably, the single opening is a through-hole configured to accommodate an inflation valve for the tire.

[0101] Preferably, in the spoked bicycle wheel according to the invention, the rim is made of aluminum or its alloy, or more preferably, of a composite material.

[0102] Preferably, in the rim of the wheel of the present invention, the spoke attachment chamber is defined between an upper bridge member and a lower bridge member of the rim, the upper bridge member separating the tire connection channel from the spoke attachment chamber, and the lower bridge member including a spoke attachment surface. Attached Figure Description

[0103] Further features and advantages of the present invention will become clearer from the description of its preferred embodiments with reference to the accompanying drawings, in which:

[0104] Figure 1 This is a schematic perspective view of a portion of a spoked bicycle wheel according to the present invention;

[0105] Figure 2 This is a longitudinal cross-sectional view of a first preferred embodiment of the spoke attachment assembly according to the present invention;

[0106] Figure 3 It is formed Figure 2 A schematic perspective view of a molded washer as part of a spoke attachment assembly;

[0107] Figure 4 This is a longitudinal cross-sectional view of a second preferred embodiment of the spoke attachment assembly according to the present invention;

[0108] Figure 5 It means that it is intended to manufacture Figure 1 A schematic diagram illustrating the steps of the wheel's process;

[0109] Figures 6 to 9 These are three-dimensional diagrams and partial cross-sectional views of the continuous steps of the aforementioned process. Detailed Implementation

[0110] First refer to Figure 1 Reference numeral 5 in the accompanying drawings generally indicates a first embodiment of a spoked bicycle wheel according to the present invention.

[0111] The wheel 5 includes a rim 10, a hub 20, and a plurality of spokes 30 extending between the hub 20 and the rim 10. For clarity of illustration, reference numeral 30 is associated with only one of the spokes shown.

[0112] Rim 10 can be made from aluminum or its alloy by extrusion of a forming rod.

[0113] Preferably, the rim 10 is at least partially made of composite material. More preferably, the rim 10 is entirely made of composite material.

[0114] The rim 10 is configured for use with tubeless tires (not shown).

[0115] The rim 10 is formed by two opposing sidewalls 16a, which are connected to the radially inner end by a radially inner circumferential wall or a lower bridging member 16b. The two sidewalls 16a are also connected at their midpoint by a radially outer circumferential wall or an upper bridging member 16c, thus having a generally inverted "A" shaped cross section.

[0116] Preferably, the lower bridging member 16b and the upper bridging member 16c have a generally cylindrical shape.

[0117] The sidewall 16a includes a corresponding radially outer portion or wing 16d, which forms a tire connection channel 12 with the upper bridge member 16c. The wing 16d is provided with a corresponding folded end 16e for retaining the bead of the tire connected to the rim 10.

[0118] The wing 16d is constrained by its geometry and dimensions, both for the purpose of attaching the tire and for providing a suitable sliding surface externally for any potential brake pads. In the case of a tubeless tire, the upper bridge member 16c is constrained by its airtight seal with the tire. In the example shown, the upper bridge member 16c has a single opening 15c for the passage and reception of either the tire's inflation valve (not shown) or the inflation valve (not shown) of the tire's air chamber.

[0119] like Figures 6 to 9 As shown, the rim 10 includes a spoke attachment chamber 14 at a radially inward position relative to the tire connection channel 12. Specifically, the spoke attachment chamber 14 is defined by the radial interior 16f of the sidewall 16a, by the lower bridge member 16b, and by the upper bridge member 16c.

[0120] The radial interior 16f of the sidewall 16a and the lower bridging member 16b are not constrained by a particular geometry or size, and therefore can be replaced by a single wall with a circular arc cross-section or by multiple walls to form a cross-section with a more complex shape than that shown, possibly defining multiple annular spoke attachment chambers (not shown).

[0121] therefore, Figure 1 and Figures 6 to 9 The specific shape of the rim 10 shown is merely illustrative and not limiting of the invention.

[0122] like Figures 6 to 9As shown, the lower bridge member 16b includes a spoke attachment surface 17 on which an opening 15b is formed. This opening 15b is substantially aligned in the radial direction with an opening 15c formed on the upper bridge member 16c, and the opening 15b is also provided for the passage and reception of a tire inflation valve, or for the passage and reception of an inflation valve for a tire air chamber.

[0123] In one embodiment of the rim 10, the aforementioned openings 15b and 15c are defined by corresponding through holes with a diameter between about 6 mm and about 9 mm, for example, equal to 7 mm.

[0124] like Figure 1 As shown, the spoke attachment surface 17 includes a plurality of spoke attachment seats 18, each spoke attachment seat 18 being defined by a corresponding through hole. For clarity of illustration, reference numeral 18 is associated with only one of the spoke attachment seats shown.

[0125] In embodiments different from those shown, spoke attachment seats 18 are formed in one or both of the radial interior 16f of the sidewall 16a of the rim 10.

[0126] The spoke attachment seats 18 are equidistantly spaced and evenly distributed along the center plane of the rim 10. However, the number and distribution of such spoke attachment seats 18 can be quite different from the number and distribution of the embodiment shown herein. For example, the spoke attachment seats 18 may be divided into two, three, or four groups and / or made on multiple planes other than the center plane of the rim 10.

[0127] Preferably, each spoke attachment 18 has a generally circular cross-section and is defined by a through hole with a diameter smaller than that of the through holes defining the openings 15b and 15c. The diameter of the through hole defining the spoke attachment 18 is preferably between about 2.5 mm and about 7 mm, for example, equal to about 5 mm.

[0128] To insert the spoke attachment assembly 80 into the spoke attachment chamber 14, it is also conceivable to forgo the opening 15c and instead create a dedicated opening (not shown) on the upper bridge 16c. In this way, a broken or damaged spoke attachment assembly 80 can be replaced without disassembling and reinstalling the tire's inflation valve. This dedicated opening is preferably provided with a removable cover configured to close when not in use.

[0129] exist Figure 1 In the rim 10, the spokes 30 are connected to the rim 10 at the respective spoke attachment seats 18 via corresponding joints 40. For clarity of illustration, reference numeral 40 is associated with only one of the joints shown.

[0130] like Figure 2As shown, the connector 40 includes a post 42 and an enlarged head 44 (i.e., having an outer dimension larger than that of the post 42), the post 42 being configured to extend through the spoke attachment seat 18, and the enlarged head 44 being configured to remain inside the spoke attachment chamber 14.

[0131] The first end 32 of the spoke 30 is attached to the joint 40. On the other hand, the second end 34 of the spoke 30 is attached to the hub 20. Figure 1 ).

[0132] The connector 40 is preferably made of aluminum (or its alloy), brass or steel.

[0133] In the embodiments shown herein, each joint 40 allows for tension adjustment of the spokes 30 associated with it.

[0134] like Figure 4 As shown, for this purpose, the post 42 of the connector 40 includes a connecting portion 47 configured to connect to the spoke 30. Such a connecting portion 47 includes the post 42 ( Figure 2 A threaded hole 47a is open at the free end 42a of the spoke 30. The length of the threaded hole allows the first end 32 of the spoke 30 to be screwed in to different depths. The latter has an external thread that matches the threaded hole 47a, thereby enabling the tension of the spoke 30 to be adjusted by means of a rotary joint 40.

[0135] In the non-limiting example shown herein, the threaded hole 47a is a through hole and extends along the entire connector 40, i.e., at the post 42 and at the enlarged head 44.

[0136] The post 42 of the connector 40 is configured to insert into the corresponding spoke attachment 18, such that the radially inner end 41 protrudes radially from the lower bridging member 16b inside the rim 10, as... Figure 1 As shown, for the sake of simplicity, reference numerals 40 and 41 are associated with only one of the connectors shown.

[0137] like Figure 2 As shown, the shaped washer 50 is applied to the post 42 of each joint 40.

[0138] When the spokes 30 are tensioned, the forming washer 50 and the spoke attachment seat 18 abut concentrically against the spoke attachment surface 17 of the lower bridge 16b of the rim 10, inside the spoke attachment chamber 14 and in a radially external position relative to the lower bridge 16b, serving as a support for the enlarged head 44 of the joint 40.

[0139] The forming washer 50 has an external dimension larger than that of the spoke attachment 18 and allows for better stress distribution on the lower bridging member 16b of the rim 10 surrounding the spoke attachment 18 when the spoke 30 is tensioned.

[0140] like Figure 2 and Figure 3 As shown, the shaped washer 50 has an annular shape, having a central through hole 52, a generally flat radial inner surface 54, and a radial outer surface 56. The radial inner surface is configured to abut against the spoke attachment surface 17 of the lower bridging member 16b of the rim 10, and the radial outer surface is configured to abut against the enlarged head 44 of the connector 40.

[0141] exist Figure 2 and Figure 3 In the non-limiting example shown, the radial outer surface 56 has a generally truncated conical or spherical shape. Accordingly, the enlarged head 44 of the connector 40 has a support portion 46 with a generally truncated conical or spherical shape.

[0142] A system designed to prevent the connector 40 from unscrewing from the spoke 30 (e.g., due to vibration) is foreseeable. For example, glue can be used between the thread on the end 32 of the spoke 30 and the threaded hole 47a of the connector 40. Alternatively, at the head of the threaded end 32 of the spoke 30, particularly at a radially outer position relative to the threaded hole 47a, a perforated ball (not shown), for example made of nylon, can be arranged in a suitable seat 45a formed in the enlarged head 44 (e.g., Figure 2 (as shown in the image).

[0143] exist Figure 4 In one variant, the post 42 of the connector 40 has an additional shaped washer 60 applied thereon. This additional shaped washer 60 is located between the enlarged head 44 of the connector 40 and the shaped washer 50.

[0144] The additional molded washer 60 has an annular shape and a central through-hole 62 configured to be coaxially arranged with the central through-hole 52 of the molded washer 50. In this way, the molded washer 50 is arranged at least partially around the additional molded washer 60.

[0145] like Figure 4 As shown, the additional molded washer 60 has a generally truncated conical or spherical shape, having a radially inner truncated conical or spherical surface 64 and a radially outer truncated conical or spherical surface 66. The radially inner truncated conical or spherical surface is configured to abut against the radially outer surface 56 of the molded washer 50, and the radially outer truncated conical or spherical surface is configured to abut against the support portion 46 of the enlarged head 44 of the connector 40.

[0146] Preferably, the shaped washer 50 and the additional shaped washer 60 are made of a metal material, such as steel.

[0147] like Figure 2As shown, the enlarged head 44 of the connector 40 includes a gripping portion 48 at a radially outward position relative to the support portion 46, which in particular has a flat side 48a.

[0148] The post 42 of the connector 40 includes a generally cylindrical portion 43 at a radially outer position relative to the end 41, where a shaped washer 50 is applied, while the end 41 has a longitudinal gripping spline 41a configured to be engaged by a suitable tool (not shown) during the tensioning of the spokes 30 in order to rotate the connector 40.

[0149] like Figure 4 As shown, the insert 200 is removably associated with the connector 40.

[0150] The insert 200 is made of a metallic material, preferably steel.

[0151] The insert 200 includes a head 204 and a rod 202.

[0152] The rod 202 includes an external thread that matches the internal thread of the threaded hole 47a of the post 42 of the connector 40, so as to screw the rod 202 of the insert 200 into the post 42 of the connector 40.

[0153] The head 204 has a generally cylindrical shape, and its diameter is preferably smaller than the lateral dimension of the post 42 of the connector 40 and smaller than the diameter of the generally cylindrical portion 43 of the post 42.

[0154] In the following text, for the sake of simplicity, reference will be made to the spoke attachment assembly 80 which includes only the shaped washer 50, but the same applies to the case where the spoke attachment assembly 80 also includes the shaped washer 60.

[0155] like Figure 5 As schematically shown, the manufacture of wheel 5 includes attaching spokes 30 to rim 10 after a number of spoke attachment assemblies 80, equal to the number of spoke attachment seats 18 inserted into the spoke attachment chambers 14 of rim 10, have been inserted, and after constraining the respective spoke attachment assemblies 80 to each spoke attachment seat 18. Figure 5 In the image, the spoke attachment assembly 80 is shown in solid line during the insertion step of inserting the spoke attachment chamber 14 through the opening 15c, and the same spoke attachment assembly 80 constrained in the spoke attachment seat 18 is shown in dashed line.

[0156] Insertion of the spoke attachment assembly 80 into the rim 10 is preferably achieved by arranging the rim 10 vertically, i.e., with the axis of rotation R of the rim 10 oriented horizontally and the opening 15c facing downwards. In this way, in order to insert the spoke attachment assembly 80 into the spoke attachment chamber 14 of the rim 10, the spoke attachment assembly 80 must be arranged in an operable position such that the forming washer 50 (and possibly the forming washer 60) tends to be held against the post 42 of the connector 40 due to gravity. Such an operable position is any position in which at least a portion of the enlarged head 44 of the connector 40 is lower relative to the free end of the post 42 of the connector 40, and the post 42 of the spoke attachment assembly 40 extends along a longitudinal direction inclined relative to the horizontal direction. In such an operable position, the forming washer 50 tends to be pushed against the enlarged head 44 of the connector 40 and may abut against it.

[0157] The aforementioned operable position is maintained during the insertion of the spoke attachment assembly 80 into the spoke attachment chamber 14 and until the post 42 of the connector 40 of the spoke attachment assembly 80 is brought to the spoke attachment surface 17 of the lower bridge 16b of the rim 10.

[0158] exist Figure 5 In the schematic example, the opening 15c is arranged such that the insertion of the spoke attachment assembly 80 into the spoke attachment chamber 14 is along the vertical insertion direction d, i.e., inclined at an angle α of 90° relative to the horizontal plane P arranged below the rim 10. Figure 5 In the diagram, two other possible insertion directions d are also shown by dashed lines, each of which is inclined relative to the aforementioned horizontal plane P by a predetermined angle α different from 90°. Angle α is preferably included in the range of 0° to 180°, excluding extreme values. Therefore, preferably, the insertion direction d is not horizontal.

[0159] Insertion of the spoke attachment assembly 80 into the spoke attachment chamber 14 of the rim 10 is carried out along the insertion direction d based on an insertion feel oriented from bottom to top (as already described, this bottom-to-top orientation is not necessarily along the vertical direction). First, the post 42 is inserted into the opening 15c, and then the enlarged head 44 of the connector 40 is inserted into the opening 15c. Thus, during the insertion of the spoke attachment assembly 80 into the spoke attachment chamber 14, as the spoke attachment assembly 80 moves along the insertion direction d, this insertion direction is oriented to gradually move away from the plane P.

[0160] Figures 6 to 9 The steps for inserting the connector 40 and the associated shaped washer 50 into the rim 10 and positioning them in the spoke attachment seat 18 are shown.

[0161] Figure 6The insertion steps are shown, in which the spoke attachment assembly 80 is inserted into the opening 15c of the upper bridge member 16c of the rim 10 of the wheel 5 along the insertion direction d and according to the above-mentioned insertion sensation.

[0162] Specifically, the spoke attachment assembly 80 shown is a reference. Figure 2 One of the described embodiments, but it could also be Figure 4 one of the.

[0163] In addition to the connector 40 and the shaped washer 50 held on the connector 40 by gravity, the spoke attachment assembly 80 also includes a reference Figure 4 The described insert 200 is screwed into the post 42 of the connector 40.

[0164] A manipulating magnet 300 is magnetically attached to the head 204 of the insert 200. In the example shown, the manipulating magnet 300 has a generally elongated shape (e.g., cylindrical) and is arranged such that its end 302 is magnetically locked to the head 204 of the insert 200. Specifically, the manipulating magnet 300 is arranged to be substantially aligned with the post 42 of the connector 40 (and thus substantially aligned with the insertion direction d) and to contact the head 204 of the insert 200.

[0165] The external dimensions of the manipulating magnet 300 may be approximately equal to or different from the external dimensions of the post 42 of the connector 40.

[0166] The manipulating magnet 300 is first inserted into the opening 15c in the upper bridging member 16c of the rim 10, and after its movement along the insertion direction d, it is inserted into the opening 15b in the lower bridging member 16b of the rim 10, thereby pulling the spoke attachment assembly 80 into the spoke attachment chamber 14 of the rim 10.

[0167] Figure 7 The procedure for removing the manipulating magnet 300 from the opening 15b of the lower bridging member 16b of the rim 10 along the insertion direction d is shown.

[0168] After this, the manipulator 300 is disconnected from the head 204 of the insert 200.

[0169] Simultaneously, the guide magnet 310 is brought close to the opening 15b. The guide magnet 310 then engages in magnetic interaction with the insert 200 (particularly with the head 204 of the insert 200).

[0170] like Figure 8 As shown, the guide magnet 310 moves along and outside the spoke attachment surface 17 of the lower bridging member 16b of the rim 10, thereby pulling the spoke attachment assembly 80 along the spoke attachment chamber 14 of the rim 10 by magnetic attraction until it reaches the spoke attachment seat 18 in which the connector 40 and the forming washer 50 are to be arranged.

[0171] At this time, as Figure 9 As shown, the guide magnet 310 is magnetically locked to the head 204 of the insert 200. Specifically, the guide magnet 310 contacts the head 204 of the insert 200 and remains in contact with it due to the magnetic interaction between the guide magnet 310 and the insert 200.

[0172] Subsequently, the guide magnet 310 is moved radially toward the inside of the rim 10 so as to insert the post 42 of the connector 40 into the spoke attachment seat 18 until the forming washer 50 abuts against the spoke attachment surface 17 of the lower bridging member 16b of the rim 10.

[0173] Therefore, during the manufacture of wheel 5, guide magnet 310 can be disengaged from head 204 of insert 200, and insert can be removed from joint 40 to continue installing and tensioning spokes 30 on joint 40, or to continue installing anchoring elements configured to hold joint 40 in the proper position in the corresponding spoke attachment 18 until the moment such anchoring elements are removed during the manufacture of wheel 5 to continue installing spokes 30 on joint 40.

[0174] The installation of spokes 30 on joint 40 requires temporarily holding joint 40 with fingers or a gripping tool.

[0175] As already explained, although the insertion direction d of the spoke attachment assembly 80 in the spoke attachment chamber 14 of the rim 10 is preferably not horizontal, the post 42 of the connector 40 can also be inserted in the horizontal insertion direction d if the post 42 of the connector 40 extends in the horizontal direction. In this case, gravity tends to push the forming washer 50 onto the post 42 of the connector 40, and therefore, in the same case, the forming washer 50 tends to remain applied to the post 42 of the connector 40.

[0176] Of course, those skilled in the art can make various modifications and variations to the present invention to meet specific and occasional needs, all of which are within the scope of protection defined by the claims in any case.

[0177] In particular, any combination of features described with reference to different variants of the spoke attachment assembly 80 described above may be provided.

[0178] The wheel 5 of the present invention can receive both tires with air chambers and tubeless tires.

[0179] The upper bridging member 16c of the rim may or may not include additional openings and opening 15c. In any case, the number of openings made on the upper bridging member 16c is less than the number of spoke attachment seats 18 made on the spoke attachment surface 17 of the lower bridging member 16b.

[0180] The manipulating magnet 300 may have an external dimension that is greater than, less than or equal to the inner diameter of the shaped washer 50.

[0181] The head 204 of the insert 200 may have an external dimension that is greater than, less than or equal to the inner diameter of the shaped washer 50.

[0182] The function of the aforementioned guide magnet 310 can also be performed by the manipulation magnet 300 itself, so that in this variant, only the manipulation magnet 300 is used in the manufacturing process of the wheel 5.

[0183] To move the spoke attachment assembly 80 along the spoke attachment chamber 14 of the rim 10 until it reaches the predetermined spoke attachment seat 18, instead of the guide magnet 310, a semi-rigid cable can be used, i.e., a cable that is flexible enough to conform to the shape of the spoke attachment chamber 14, but rigid enough to be pushed along the spoke attachment chamber 14, such as the cable described in US2007 / 0158996A1.

Claims

1. Process aimed at manufacturing a spoke bicycle wheel (5), comprising the following steps: a) providing a rim element having a tire coupling channel (12) and at least one spoke attachment chamber (14) provided with at least one opening (15c) and with a spoke attachment surface (17) comprising a plurality of spoke attachment seats (18); b) providing a spoke attachment assembly (80) comprising: - a joint (40) having an enlarged head (44) and a stem (42) provided with a coupling portion (47) configured to be coupled to a respective spoke (30); - at least one shaped washer (50, 60) applied to the stem (42) of the joint (40); c) inserting the spoke attachment assembly (80) into the at least one spoke attachment chamber (14) through the at least one opening (15c) by first inserting the stem (42) of the joint (40) into the opening (15c) and then inserting the enlarged head (44) of the joint (40) into the opening (15c), along an insertion direction (d) inclined with respect to a horizontal plane (P) arranged below the rim element and according to an insertion sense oriented away from the horizontal plane (P) and so that the at least one shaped washer (50, 60) remains applied to the stem (42) of the joint (40) due to gravity; d) moving the spoke attachment assembly (80) along the insertion direction (d) until bringing the stem (42) of the joint (40) at the spoke attachment surface (17), so as to bring the at least one shaped washer (50, 60) into abutment with the spoke attachment surface (17); e) moving the spoke attachment assembly (80) along the spoke attachment surface (17) and up to one of the spoke attachment seats (18); f) inserting the stem (42) of the joint (40) of the spoke attachment assembly (80) into the spoke attachment seat (18); g) constraining the spoke attachment assembly (80) to the spoke attachment seat (18); h) repeating steps c) to g) so as to couple a respective spoke attachment assembly (80) to each of the plurality of spoke attachment seats (18).

2. Process according to claim 1, wherein the step c) of inserting the spoke attachment assembly (80) into the at least one spoke attachment chamber (14) comprises associating the spoke attachment assembly (80) with a handling device configured to move the spoke attachment assembly (80) towards the spoke attachment surface (17).

3. Process according to claim 2, wherein the spoke attachment assembly (80) further comprises a portion made of magnetically attractable material and wherein the handling device comprises a handling magnet (300).

4. Process according to claim 3, wherein said portion made of magnetically attractable material is defined by an insert (200) made of a metallic material and having a head (204) and an at least partially threaded stem (202) screwed into a threaded hole (47a) made in said column (42) of said joint (40).

5. Process according to claim 3, wherein step c) of inserting said spoke attachment assembly (80) into said at least one spoke attachment chamber (14) comprises the following steps: - coupling said handling magnet (300) to said spoke attachment assembly (80) due to the magnetic interaction between said handling magnet (300) and said portion made of magnetically attractable material; - inserting said handling magnet (300) into said at least one spoke attachment chamber (14) through said at least one opening (15c); - extracting said handling magnet (300) from said at least one spoke attachment chamber (14) through a second opening (15b) substantially aligned with said at least one opening (15c); - decoupling said handling magnet (300) from said spoke attachment assembly (80).

6. Process according to claim 5, wherein step e) of moving said spoke attachment assembly (80) is preceded by the step of keeping said spoke attachment assembly (80) in contact with said spoke attachment surface (17) by decoupling said handling magnet (300) from said spoke attachment assembly (80) and simultaneously magnetically coupling said spoke attachment assembly (80) to a guiding magnet (310) facing the rim element proximally to said second opening (15b).

7. Process according to claim 6, wherein step e) of moving said spoke attachment assembly (80) is performed due to the magnetic interaction between said portion made of magnetically attractable material and said guiding magnet (310) and comprises moving said guiding magnet (310) along said rim element towards and up to one said spoke attachment seat (18).

8. Process according to claim 7, wherein step f) of inserting said column (42) of said joint (40) into said spoke attachment seat (18) is performed due to the magnetic coupling between said guiding magnet (310) and said portion made of magnetically attractable material.

9. The process of claim 1, wherein the step f) of inserting the stem (42) of the joint (40) into the spoke attachment seat (18) comprises: - abutting said at least one shaped washer (50, 60) against said spoke attachment surface (17) and said enlarged head (44) of said joint (40) against said at least one shaped washer (50, 60).

10. Process according to claim 1, wherein step g) of constraining said spoke attachment assembly (80) to said spoke attachment seat (18) comprises coupling said column (42) of said joint (40) to an anchoring element configured to attach said joint to said spoke attachment seat (18).

11. The process of claim 1, wherein the step g) of constraining the spoke attachment assembly (80) to the spoke attachment seat (18) comprises securing an end portion (32) of a spoke (30) to the coupling portion (47) of the post (42) of the nipple (40).

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