Reinforced thermoplastic parts and methods of making the same

Abstract

Systems and techniques for manufacturing complex components using reinforced thermoplastic materials are disclosed herein. The complex components can include an outer surface having a contour or curvature, and in some cases define a cavity. In certain examples, one or more thermoplastic materials are arranged to form a wheel component, such as a wheel component adapted to define a self- supporting wheel rim. Thermal bonding can be used to connect multiple reinforced thermoplastic materials to one another to form a cavity or other complex shape of the wheel component. In certain examples, a portion of a mold assembly can be pressurized to maintain the shape of the cavity during thermal bonding and cooling. This can eliminate the need for a sacrificial bladder or other structure to maintain the shape of the cavity, thereby allowing a seamless final component, optionally without indicia of bladder exit or other seams.

Description

[0001] Cross Reference to Related Applications

[0002] This application claims priority to U.S. Provisional Application No. 62 / 908,320, filed September 30, 2019, entitled “Reinforced Thermoplastic Components and Method of Manufacture Thereof,” and U.S. Provisional Patent Application No. 62 / 982,611, filed February 27, 2020, entitled “Reinforced Thermoplastic Components and Method of Manufacture,” the disclosures of which are incorporated herein by reference in their entirety. TECHNICAL FIELD

[0003] The described embodiments relate generally to high-strength, lightweight structures formed from reinforced thermoplastic materials, and more specifically, to structures formed from reinforced thermoplastic materials that can define hollow cavities. BACKGROUND

[0004] Composite materials can include a combination of two or more different materials that work in a manner that complements and enhances the material properties of each. For example, composite materials can include a combination of a relatively lightweight material and a relatively high-strength material to produce a part with a high strength-to-weight ratio. Such parts can include complex shapes and designs, including shapes tailored for a particular purpose. For example, a part for a particular purpose can include a shape with a contoured surface, such as a curved exterior. The part can also have a hollow interior to reduce weight. In many traditional systems, thermoset materials are used to hold the reinforcing material in the matrix. Traditional methods can produce parts that are overly brittle and limit the adaptability of the part and manufacturing. Further, traditional manufacturing to form a part from a composite material and produce a shape with a hollow interior can involve a complex, multi-step process that increases cost and can result in discontinuities or inconsistencies. Accordingly, there is a continuing need for techniques that can enhance the range of composite part shapes and structures without limiting the functionality or performance of the overall design. SUMMARY

[0005] Examples of the present systems and methods relate to reinforced thermoplastic components. More specifically, examples described herein relate to reinforced thermoplastic components having complex shapes, such as shapes having curved profiles, substantially hollow interiors, and / or other attributes. In certain examples, the reinforced thermoplastic components described herein can be used to form wheel components, such as wheels for bicycles. Reinforced thermoplastic materials can be used to form fully continuous circular components that form a wheel. Wheel components or other structures formed from reinforced thermoplastic materials can be substantially hollow structures. Techniques are disclosed herein for forming wheel components using one or more reinforced thermoplastic materials to form wheel components having hollow interiors and curved outer surfaces, including where the wheel components have substantially circular hollow cavities and continuous circular outer shapes.

[0006] In one example, a wheel component is disclosed. The wheel component includes a rim base portion defining an outer annular surface of the wheel component configured to engage a bicycle tire. The wheel component also includes a main structural portion defining a cavity with the rim base portion. The rim base portion and the main structural portion are each formed from a reinforced thermoplastic material. The rim base portion and the main structural portion are bonded to one another to form a unitary structure.

[0007] In another example, the main structural portion can include a wall portion formed from the reinforced thermoplastic material. The reinforced thermoplastic material of the wall portion can include a plurality of plies that overlap one another and define radially intersecting plies. The plurality of plies can include a first ply having a first edge. The first edge can define an offset angle between 22.5 and 75 degrees from a central axis of a continuous circle defined by the outer annular surface.

[0008] In another example, the plurality of plies can include a second ply having a second edge. The second ply can overlap the first ply, where the first edge and the second edge are substantially transverse to one another. In some examples, the first ply and the second ply can define an arrangement of plies. The wheel component can also include the arrangement of a plurality of plies disposed in a radial pattern to define the wall portion.

[0009] In another example, the rim base portion and the main structural portion can be at least one of thermally bonded, chemically bonded, or adhesively bonded.

[0010] In another example, the main structural portion can define an inner annular surface of the wheel component configured to receive a series of spokes. The main structural portion can be configured to withstand a pulling force associated with the series of spokes of at least 300 pounds. The main structural portion can define a reinforcement layer along the inner annular surface.

[0011] In another example, the reinforced thermoplastic material includes a thermoplastic material and fibers held within the thermoplastic material. The fibers can include one or more of carbon fibers, glass fibers, Kevlar fibers, or basalt fibers. In some examples, the fibers can define at least 30% of a volume of the reinforced thermoplastic material.

[0012] In another example, a wheel component is disclosed. The wheel component can include a continuous reinforced thermoplastic material and can have a rim base portion and a main structure portion connected to the rim base portion. The continuous reinforced thermoplastic material defines a circular cavity therethrough. An outer surface of the wheel component can be defined by the rim base portion, and the main structure portion can be free of indicia associated with a bladder exit from the cavity.

[0013] In another example, the indicia can include a through portion of the wheel component extending between the circular cavity and an external environment having a lateral dimension greater than 15 mm. Further, the outer surface can cooperate to completely seal the circular cavity from the external environment. The continuous reinforced thermoplastic material can include a stack of reinforced thermoplastic segments overlapping one another to define a radial cross-ply. The radial cross-ply can extend along a sidewall of the main structure portion.

[0014] In another example, the circular cavity can be formed by maintaining a pressurized region between the rim base portion and the main structure portion during a thermal bonding process. The pressurized region can be maintained without an internal bladder, thereby allowing the outer surfaces of the rim base portion and the main structure portion to be free of indicia typically associated with a bladder exit from the cavity.

[0015] In another example, the circular cavity is self-sealing. The continuous reinforced thermoplastic material can exhibit a flexural strength of at least 740 MPa.

[0016] In another example, a method of manufacturing a fully reinforced thermoplastic wheel component is disclosed. The method includes forming a rim base portion from a first reinforced thermoplastic material. The method also includes forming a main structure portion from a second reinforced thermoplastic material. The method further includes forming the fully reinforced thermoplastic wheel component as a continuous circular component by thermally bonding the rim base portion and the main structure portion to one another within a mold compartment.

[0017] In another example, forming the main structure can include defining a radial cross-ply by arranging a first ply of the second reinforced thermoplastic material relative to a second ply of the second reinforced thermoplastic material. One or both of the first ply or the second ply defines an off-angle relative to the central axis between 22.5 and 75 degrees. The forming of the main structure portion can include stamping the second reinforced thermoplastic material to define an inner annular surface configured to be associated with a series of spokes.

[0018] In another example, the operations to form the fully reinforced thermoplastic wheel component can include heating the first reinforced thermoplastic material and the second reinforced thermoplastic material above a melting temperature. The operations to form the fully reinforced thermoplastic wheel component can also include defining the cavity between the rim base portion and the main structure portion by pressurizing a region of the mold compartment substantially between the rim base portion and the main structure portion.

[0019] In another example, a wheel component is disclosed. The wheel component includes a rim base portion defining an outer annular surface of the wheel component configured to engage a bicycle tire. The wheel component also includes a main structure portion defining a cavity with the rim base portion. The rim base portion and the main structure portion are each formed from a reinforced thermoplastic material. Further, the rim base portion and the main structure are thermally bonded to one another to form a unitary structure.

[0020] In another example, the main structure portion can define an inner annular surface of the wheel component that can be configured to receive a series of spokes. The series of spokes can be engaged with the main structure portion to exhibit a pull force of at least 300 pounds from the wheel component. Additionally or alternatively, the series of spokes can be engaged with the main structure portion to exhibit a pull force of at least 400 pounds from the wheel component. Additionally or alternatively, the series of spokes can be engaged with the main structure portion to exhibit a pull force of at least 500 pounds from the wheel component.

[0021] In another example, the rim base portion can be at least partially seated within the main structure portion. In some cases, the main structure portion includes a first wall portion and a second wall portion. The cavity can be at least partially defined by each of the rim base portion, the first wall portion, and the second wall portion. The first wall portion and the second wall portion can be interconnected by a lap joint. Additionally or alternatively, the second wall portion can define a reinforcement layer along an annular surface defined by the first wall portion. In some examples, the main structure portion can also include a third wall portion. In this regard, the cavity can be defined by each of the rim base portion, the first wall portion, the second wall portion, and the third wall portion.

[0022] In another example, the rim base portion includes a first rim wall portion and a second rim wall portion. The cavity can be at least partially defined by each of the first rim wall portion, the second rim wall portion, and the main structure portion.

[0023] In another example, the unitary structure can define a continuous circular shape.

[0024] In another example, the reinforced thermoplastic material can include a thermoplastic material. The reinforced thermoplastic material can also include fibers held within the thermoplastic material. The fibers can include one or more of carbon fibers, glass fibers, Kevlar fibers, and / or basalt fibers. In some examples, the fibers can define at least 40% of a volume of the reinforced thermoplastic material. Additionally or alternatively, the fibers can define at least 70% of a volume of the reinforced thermoplastic material. In certain applications, the reinforced thermoplastic material can also include resin-impregnated spread carbon fiber tows.

[0025] In another example, the wheel component also includes a spoke portion formed from the reinforced thermoplastic material. The spoke portion can be thermally bonded with the main structure portion to form a unitary structure including each of the rim base portion, the main structure portion, and the spoke portion. In this regard, the wheel component can also include a hub portion formed from the thermoplastic material. The hub portion can be thermally bonded with the spoke portion to form a unitary structure including each of the rim base portion, the main structure portion, the spoke portion, and the hub portion. Although many shapes are possible and described herein, in some examples, the unitary structure can define a three-spoke shape.

[0026] In another example, a wheel component is disclosed. The wheel component includes a continuous reinforced thermoplastic material having a rim base portion and a main structure portion connected to the rim base portion. The continuous reinforced thermoplastic material defines a circular cavity therethrough. An outer surface of the wheel component is defined by the rim base portion and the main structure portion and is free of indicia associated with a bladder exiting the cavity.

[0027] In another example, the indicia can include a through portion of the wheel component extending between the circular cavity and an external environment and having a lateral dimension greater than 20 mm. Additionally or alternatively, the indicia can include a through portion of the wheel component extending between the circular cavity and an external environment and having a lateral dimension greater than 10 mm. The outer surface is fitted to completely seal the circular cavity from the external environment.

[0028] In another example, the circular cavity can be formed by maintaining a pressurized region between the rim base portion and the main structure portion during a thermal bonding process. The pressurized region can be maintained without an internal bladder, thereby allowing the outer surface of the rim base portion and the main structure portion to be free of indicia associated with a bladder exiting the cavity.

[0029] In another example, a portion of the pneumatic component can be within the circular cavity and thermally bonded to the main structure portion. The portion of the pneumatic component can have a melting temperature that is higher than a melting temperature of the main structure portion. The portion of the pneumatic component can have a melting temperature that can be higher than the melting temperature of the main structure portion and a melting temperature of the rim base portion.

[0030] In another example, the wheel component can include a membrane within the circular cavity. The membrane can be adapted to define a self-sealing, permanent bladder within the circular cavity. In some examples, the membrane can be formed of a nylon material. The melting temperature of the membrane can be higher than the melting temperature of one or both of the main structural portion or the rim base portion.

[0031] In another example, the main structural portion can define a reinforced region along the inner annular region of the wheel component. The reinforced region can include a plurality of reinforced thermoplastic layers thermally bonded to one another. The main structural portion can include a first wall portion and a second wall portion, each wall portion overlapping along the inner annular region. In some examples, the reinforced region is configured to establish a spoke pull of at least 500 pounds.

[0032] In another example, the continuous reinforced thermoplastic material includes fiber filaments suspended in a resin matrix. The fiber filaments can be arranged in a compact configuration adjacent to one another within the resin matrix. The continuous reinforced thermoplastic material includes a nanocoating around the fiber filaments therein for bonding the filaments to the resin matrix. While many materials are possible, the fiber filaments can include one or more of carbon fiber, glass fiber, Kevlar fiber, or basalt fiber. In some examples, the continuous reinforced thermoplastic material can exhibit a bending strength of at least 740 MPa.

[0033] In another example, a method of manufacturing a fully reinforced thermoplastic wheel component is disclosed. The method includes arranging a rim base portion and a main structural portion within a mold compartment. The rim base portion and the main structural portion are formed of a reinforced thermoplastic material. The method further includes pressurizing a region of the compartment between the rim base portion and the main structural portion. The method further includes bonding the rim base portion and the main structural portion by heating the reinforced thermoplastic material above a melting temperature. The method further includes sealing a cavity defined by the rim base portion and the main structural portion.

[0034] In another example, the heating operation includes exposing the mold compartment to a heat source having a temperature of at least 450 degrees Fahrenheit. The operation of arranging the rim base portion and the main structural portion within the mold compartment can include sealing the rim base portion at least partially within the main structural portion.

[0035] In another example, the primary structural portion can include a first wall portion and a second wall portion. In this regard, the operation of arranging can include overlapping the first wall portion and the second wall portion along the inner annular surface of the wheel component. In some examples, the operation of arranging can include each of mechanically engaging the first wall portion with a first side of the rim base portion and mechanically engaging the second wall portion with a second side of the rim base portion opposite the first side of the rim base portion. Further, the operation of joining can include defining an edge joint along the mechanical engagement of each of the first wall portion with the first side of the rim base portion and the second wall portion with the second side of the rim base portion.

[0036] In another example, the pressurizing operation includes delivering pressurized fluid into a region of a compartment between the rim base portion and the primary structural portion. The pressurized fluid can be configured to maintain the region at a pressure greater than 40 psi. The pressurized fluid can include compressed air.

[0037] In one example, the pressurizing operation includes contouring a region of a compartment between the rim base portion and the primary structural portion with a sacrificial material to define a cavity. In this regard, the sealing operation can include allowing the reinforced thermoplastic material to self-seal at an entry point of the pressurized fluid delivery. In some examples, the method further includes, prior to the operation of arranging, laying up a higher melt temperature material to one or both of the rim base portion or the primary structural portion. The higher melt temperature material can be a reinforcement panel or an embossed shape of film laid up to one or both of the rim base portion or the primary structural portion.

[0038] In another example, the pressurizing operation can include at least partially inserting a portion of an inflation component into a region of a compartment between the rim base portion and the primary structural portion. The portion of the inflation component can include a consumable portion adapted to seal an entry point of the pressurized fluid delivery. Further, the portion of the inflation component can also include a thermoplastic material having a melt temperature higher than a melt temperature of the reinforced thermoplastic material used to form the rim base portion or the primary structural portion. In some examples, the sealing operation can include sealing a thermoplastic plug at the entry point.

[0039] In one example, the joining operation defines a unitary structure comprised of the rim base portion and the primary structural portion. The unitary structure can be a continuous circular structure.

[0040] In another example, a method of manufacturing a fully reinforced thermoplastic wheel component is disclosed. The method can include forming a rim base portion from a first reinforced thermoplastic material, forming a primary structural portion from a second reinforced thermoplastic material, and forming the fully reinforced thermoplastic wheel component as a continuous circular component by thermally joining the rim base portion and the primary structural portion to one another within a mold compartment.

[0041] In another example, the operations to form the rim base portion can include stamping a first reinforced thermoplastic material to define an outer annular surface configured to engage a bicycle tire. The operations to form the main structure portion can include stamping a second reinforced thermoplastic material to define an inner annular surface configured to associate with a series of spokes.

[0042] In another example, the method can further include providing the first reinforced thermoplastic material and the second reinforced thermoplastic material from a common reinforced thermoplastic material having fiber tows disposed within a resin material. The fiber tows can be compacted relative to one another within the resin material. In some examples, the fiber tows can be arranged as a matrix having a width substantially greater than a height, the matrix defining a spread tow.

[0043] In another example, the operations to form the fully reinforced thermoplastic wheel component can include heating the first reinforced thermoplastic material and the second reinforced thermoplastic material above a melting temperature. Further, the operations to form the fully reinforced thermoplastic wheel component can include defining a cavity between the rim base portion and the main structure portion by pressurizing a region of the mold compartment substantially between the rim base portion and the main structure portion. Further, the operations to form the fully reinforced thermoplastic wheel component can include arranging the rim base portion, the main structure portion, and a sacrificial bladder in the mold compartment, the sacrificial bladder configured to maintain a pressure of at least 40 psi in the region. In this regard, the method can further include removing the sacrificial bladder through at least one of the rim base portion or the main structure portion.

[0044] In another example, the operations to form the fully reinforced thermoplastic wheel component can include reinforcing an inner annular surface of a continuous circular component. The method can further include associating a series of spokes with the inner annular surface. In some examples, the reinforced inner annular surface and the series of spokes cooperate to exhibit a pull force of at least 500 pounds.

[0045] In another example, a method of manufacturing a fully reinforced thermoplastic wheel component is disclosed. The method includes laying up a membrane to a reinforced thermoplastic material. The membrane has a higher melting temperature than the reinforced thermoplastic material. The method further includes defining a cavity with the reinforced thermoplastic material and the laid-up membrane. The method further includes sealing the cavity using the membrane.

[0046] In another example, the reinforced thermoplastic material can include a reinforcement panel or a stamp shape of the rim base portion or the main structure portion. The rim base portion and the main structure portion can be arranged to form the fully reinforced thermoplastic wheel component. In this regard, the method can further include stamping the reinforcement panel and the laid-up membrane to form the stamp shape of the rim base portion or the main structure portion.

[0047] In another example, the sealing operation can include using the membrane to allow the entry point of the pressurized fluid to self-seal. In this regard, the method can further include pressurizing the cavity by at least partially inserting an inflation member through the entry point. In some examples, the inflation member can be configured to maintain a pressure of at least 40 psi within the cavity. The defining operation can include subjecting the reinforced thermoplastic material to a heat bonding process to form a unitary structure that defines the wheel component.

[0048] In another example, the unitary structure can be a continuous circular component. The reinforced thermoplastic material can include reinforcing fibers including one or more of carbon fibers, glass fibers, Kevlar fibers, or basalt fibers.

[0049] In another example, a method of manufacturing a fully reinforced thermoplastic wheel component is disclosed. The method includes arranging a rim base portion and a main structure portion to define a cavity of the fully reinforced thermoplastic wheel component. The method further includes pressurizing the cavity by at least partially inserting an inflation member into the cavity. The inflation member is at least partially formed of a material having a melting temperature that is higher than a melting temperature of a material used to form the rim base portion and the main structure portion. The method further includes sealing the cavity using the inflation member.

[0050] In another example, the sealing operation can include defining an entry point into the cavity for insertion of a portion of the inflation member. The entry point can be defined by an annular surface defined by the rim base portion. The sealing operation can include co-curing the portion of the inflation member to the main structure portion.

[0051] In another example, the method further includes severing a portion of the inflation member from a remaining portion of the inflation member, the portion of the inflation member being at least partially retained within the cavity. The sealing operation can include using the portion of the inflation member to seal the cavity from an external environment.

[0052] In another example, the method further includes thermally bonding the rim base portion and the main structure portion to one another. Using the portion of the inflation member as a consumable within the cavity, the thermal bonding can allow an outer surface of the wheel component to be formed without indicia associated with the ejection of the bladder from the cavity.

[0053] In addition to the exemplary aspects and embodiments described above, others will become apparent to those of ordinary skill in the art by reviewing the accompanying drawings and the following description. BRIEF DESCRIPTION OF DRAWINGS

[0054] The present disclosure will be readily understood by those skilled in the art from the following detailed description in conjunction with the accompanying drawings, wherein like reference numerals designate like structural elements, and in which:

[0055] Figure 1 A sample bicycle is depicted;

[0056] Figure 2 Detail 1-1 depicting a wheel component of Figure 1

[0057] Figure 3A Detail 1-2 depicting a reinforced thermoplastic rim formed as an integral circular structure;

[0058] Figure 3B Detail 1-3 depicting a cross-sectional view of the reinforced thermoplastic material of Figure 3A taken along line 3B-3B of Figure 3A for forming a fully thermoplastic rim;

[0059] Figure 4 Detail 1-4 depicting an example of a wheel component formed from reinforced thermoplastic material;

[0060] Figure 5A Detail 1-5 depicting another example of a wheel component formed from reinforced thermoplastic material;

[0061] Figure 5B Detail 1-6 depicting another example of a wheel component formed from reinforced thermoplastic material;

[0062] Figure 5C Detail 1-7 depicting another example of a wheel component formed from reinforced thermoplastic material;

[0063] Figure 6 Detail 1-8 depicting another example of a wheel component formed from reinforced thermoplastic material;

[0064] Figure 7A Detail 1-9 depicting an operation of forming a rim base portion of a wheel component;

[0065] Figure 7B depicts an operation of forming a main structural portion of a wheel component;

[0066] Figure 7C depicts another operation of forming a main structural portion of a wheel component;

[0067] Figure 7D Detail 2-1 depicting an operation of laying up a higher melt temperature film ply to a press formed shape of a wheel component;

[0068] Figure 7E Detail 2-2 depicting an operation of laying up a higher melt temperature film ply to a reinforcement panel prior to a press operation;

[0069] Figure 8A Detail 3-1 depicting an example layup of radial cross-ply plies for manufacturing a reinforced thermoplastic component;

[0070] Figure 8B Detail 4-1 depicting a wall portion of a wheel component having radial cross-ply plies;

[0071] Figure 9A ​Another example stack for making a radial cross-ply of a reinforced thermoplastic part is depicted;

[0072] Figure 9B Another example stack for making a radial cross-ply of a reinforced thermoplastic part is depicted;

[0073] Figure 9C Another example stack for making a radial cross-ply of a reinforced thermoplastic part is depicted;

[0074] Figure 9D Another example stack for making a radial cross-ply of a reinforced thermoplastic part is depicted;

[0075] Figure 10A A set of components for making a wheel component entirely from reinforced thermoplastic material is depicted;

[0076] Figure 10B An assembly for heat bonding a reinforced thermoplastic part to form a wheel component is depicted;

[0077] Figure 10C Another assembly for heat bonding another reinforced thermoplastic part to form another example of a wheel component is depicted;

[0078] Figure 11 A cross-sectional view of the assembly of FIG. 10 taken along line 11-11 of Figure 10C is depicted;

[0079] Figure 12 An arrangement for pressurizing a cavity of a wheel component with a consumable inflatable component is depicted;

[0080] Figure 13 A cross-sectional view of the assembly of Figure 14 taken along line 13-13 of Figure 14 is depicted;

[0081] Figure 14 Another assembly for forming a continuous circular profile of a wheel component is depicted;

[0082] Figure 14 A cross-sectional view of an example of a wheel component formed from reinforced thermoplastic material and having a heat bonded joint is depicted;

[0083] Figure 15A-20B An exploded view of the wheel component of Figure 15A-20B is depicted;

[0084] Figure 15A-20B A cross-sectional view of another example of a wheel component formed from reinforced thermoplastic material and having a heat bonded joint is depicted;

[0085] Figure 15A is depicted;Figure 15A exploded view of a wheel component of

[0086] Figure 15A depicts a cross-sectional view of another example of a wheel component formed of reinforced thermoplastic material and having a heat bonded joint;

[0087] Figure 16A depicts an exploded view of a wheel component of Figure 16A

[0088] Figure 16A depicts a cross-sectional view of another example of a wheel component formed of reinforced thermoplastic material and having a heat bonded joint;

[0089] Figure 17A depicts an exploded view of a wheel component of Figure 17A

[0090] Figure 17A depicts a cross-sectional view of another example of a wheel component formed of reinforced thermoplastic material and having a heat bonded joint;

[0091] Figure 18A depicts an exploded view of a wheel component of Figure 18A

[0092] Figure 18A depicts a cross-sectional view of another example of a wheel component formed of reinforced thermoplastic material and having a heat bonded joint;

[0093] Figure 19A depicts an exploded view of a wheel component of Figure 19A

[0094] Figure 19A depicts an arrangement for performing spoke welding on a reinforced thermoplastic wheel component according to one example;

[0095] Figure 19A depicts an arrangement for performing channel welding on a reinforced thermoplastic wheel component of Figure 20A

[0096] depicts an arrangement for performing spoke welding on a reinforced thermoplastic wheel component according to another example; Figure 20A

[0097] depicts an arrangement for performing channel welding on a reinforced thermoplastic wheel component of Figure 20A Figure 21A-25B depicts an arrangement for performing spoke welding on a reinforced thermoplastic wheel component according to another example;

[0098] Figure 21A-25B depicts an arrangement for performing channel welding on a reinforced thermoplastic wheel component of

[0099] Figure 21A Figure 21A ​​​​​​arrangement for performing channel welding on a reinforced thermoplastic wheel component;

[0100] Figure 21B depicts an arrangement for performing spoke welding on a reinforced thermoplastic wheel component according to another example;

[0101] Figure 21A depicts an arrangement for performing channel welding on a reinforced thermoplastic wheel component; Figure 21A

[0102] Figure 21B depicts an arrangement for performing spoke welding on a reinforced thermoplastic wheel component according to another example;

[0103] Figure 22A depicts an arrangement for performing channel welding on a reinforced thermoplastic wheel component; Figure 22B

[0104] Figure 22A depicts another example of a wheel component formed from a reinforced thermoplastic material;

[0105] Figure 23A depicts an apparatus including a substantially hollow component formed from a thermoplastic material;

[0106] Figure 23B depicts a cross-sectional view of the substantially hollow component of Figure 23A taken along line 27B-27B of Figure 24A

[0107] Figure 24B depicts a flowchart of a method of manufacturing a fully reinforced thermoplastic wheel component;

[0108] Figure 24A depicts a flowchart of another method of manufacturing a fully reinforced thermoplastic wheel component;

[0109] Figure 25A depicts a flowchart of another method of manufacturing a fully thermoplastic wheel component;

[0110] Figure 25B depicts a flowchart of another method of manufacturing a fully thermoplastic wheel component; and

[0111] Figure 25A depicts a flowchart of a method of forming a sidewall of a fully thermoplastic wheel component.

[0112] ​​​The use of cross-hatching or shading in the drawings is generally for clarity in illustrating the underlying structure of certain elements under discussion. Accordingly, the presence or absence of cross-hatching or shading is not intended to convey or indicate any preference or requirement for any particular material, material property, element proportion, element size, commonality of the elements illustrated, or any other characteristic, attribute, or property of any element illustrated in the drawings.

[0113] Further, it should be appreciated that the proportions and dimensions of various features and elements (and collections and groupings thereof) and their border, separation, and positional relationships with one another are provided in the accompanying drawings merely for ease of understanding the various examples described herein, and are not necessarily presented or illustrated to scale, and are not intended to indicate any preference or requirement for any particular material, material property, element proportion, element size, commonality of the elements illustrated, or any other characteristic, attribute, or property of any element illustrated in the drawings. DETAILED DESCRIPTION

[0114] The description that follows includes sample systems, methods, and apparatuses that embody various elements of the disclosure. It is, however, understood that the described disclosure can be practiced in various forms other than those described herein.

[0115] The present disclosure describes systems, devices, and techniques related to enhanced thermoplastic components. More specifically, the present disclosure describes the use of enhanced thermoplastic materials to form complex shapes, including shapes having contoured or curved surfaces and / or shapes having substantially hollow interiors. As used herein, “enhanced thermoplastic materials” can include a variety of materials having reinforcing “fibers” held within a thermoplastic material. As described in greater detail below, this can include, by way of non-limiting example, certain resin types or other thermoplastic materials impregnated with reinforcing fibers including carbon fibers, glass fibers, Kevlar fibers, and / or basalt fibers, among other options described and contemplated herein. Thermoplastic materials can exhibit excellent strength-to-weight ratios, and can generally be suitable for a variety of application-specific shapes. Shapes having curved or rounded contours and / or hollow interiors can generally benefit from the strength-to-weight ratios of enhanced thermoplastic materials. However, such structures can be impeded by traditional manufacturing techniques.

[0116] Systems and techniques of the present disclosure can alleviate these impediments and produce enhanced thermoplastic components having substantially smooth, seamless, and consistently curved surfaces. Further, systems and techniques of the present disclosure can produce enhanced thermoplastic components having substantially hollow interiors. Substantially smooth, seamless, and consistently curved surfaces enhanced by substantially hollow interiors can facilitate the manufacture of wheel components formed from enhanced thermoplastic materials. More specifically, systems and techniques herein can be adapted to facilitate the manufacture of wheel components from enhanced thermoplastic materials substantially free of other filler or support-type materials.

[0117] The reinforced thermoplastic material can be used to form a unitary structure. A unitary structure can be defined as a one-piece structure. The unitary structure or one-piece or continuous structure can define a continuous circular shape or a section thereof. As described in more detail below, the unitary structure can thus be adapted to form a bicycle wheel rim. The fully reinforced thermoplastic material can provide a reduced weight ratio while exhibiting a reinforced strength that can be tailored for high performance applications. For example, a continuous circular structure formed entirely of reinforced thermoplastic material can be adapted to withstand the tensile forces of spokes in a related set of spokes of at least 300 pounds, at least 400 pounds, at least 500 pounds, or possibly greater as can be appropriate for a given application. The continuous circular structure can also be substantially free of indicia or seams or other manufacturing marks, for example, of a bladder of other sacrificial material removed from a hollow interior. This can provide an aesthetically pleasing finish to the wheel component, in addition to supporting overall performance, for example, by reducing potential failure mechanisms along where the wheel component, for example, a rim bed and a channel wall, typically meet.

[0118] While many structural embodiments of the wheel component are possible and described herein, in one example, the wheel component includes a rim bed portion defining an outer annular surface of the wheel component. The outer annular surface is shaped in a manner to engage a bicycle tire, including being substantially circular or defining a curved segment suitable to grip an outer tire or wheel component. The wheel component can also include a main structural portion that, together with the rim bed portion, defines a cavity. The main structural portion can be a structural portion of the wheel component, for example, to engage a set of spokes of the wheel component or to support other features of the wheel component in operation. In some cases, as described herein, one or both of the rim bed portion and the main structural portion can define a set of walls or other features that can be engaged with one another to form the wheel component.

[0119] In general, each of the wheel hub portion and the main structure are formed of a reinforced thermoplastic material. Where the wheel hub portion and / or the main structure includes a wall or collection of related components, all of these components are also formed of a reinforced thermoplastic material. In this regard, the wheel components can be formed as fully reinforced thermoplastic wheel components. The thermoplastic material can be impregnated with or more generally combined with reinforcing fibers to define a reinforced thermoplastic material, which can have at least 30%, at least 40%, or at least 70% fiber reinforcement by volume. In certain examples, the reinforcing fibers can be strategically arranged within the thermoplastic material. For example, the reinforcing fibers can be subjected to a spreading process during manufacturing, or other elongation and orientation techniques that allow the reinforced thermoplastic material to define spread tows (e.g., spread carbon fiber tows when carbon is used as the reinforcing fiber). Other techniques and modifications can be used on the reinforced thermoplastic material, including arranging the reinforcing fibers in a matrix, e.g., in a compact arrangement. Further, a coating or other treatment can be applied to the fibers prior to (or during) integration with the thermoplastic material to form the reinforced thermoplastic material. This can be a nano-coating that surrounds some or all of the fibers, e.g., surrounding some or all of the individual fibers to define a barrier between the fibers and the surrounding thermoplastic material.

[0120] In one example, a reinforced thermoplastic material can be used to form a wall portion of the main structure of a wheel component. The wall portion can be formed of a reinforced thermoplastic material that is composed of a plurality of plies of a reinforced thermoplastic material, such as any of the thermoplastic materials described herein. The plies can be arranged to overlap one another and collectively form a radial pattern to define the wall portion. To illustrate, the radial pattern can include a first ply having a first edge and a second ply having a second edge. The first ply and the second ply can overlap one another, e.g., overlap the first ply and the second ply such that the second edge is arranged substantially transverse to the first edge. Further, the first ply and the second ply can be arranged such that at least one of the first edge and the second edge defines an offset angle relative to a central axis of a continuous circle defined by the wheel. Sample offset angles can be between approximately 22.5 degrees and 75 degrees, such as approximately between 40 degrees and 60 degrees, e.g., preferably about 45 degrees. As described herein, the offset angle can be adjusted to optimize wall strength. The first ply and the second ply can overlap one another to define an arrangement or grouping of plies. The wall portion can include a plurality of ply arrangements to define a radial cross-ply pattern. As one illustration, the wall portion can include a multi-layer cross-ply stack, including a 6-layer cross-ply stack, with 12, 22, or more overlapping courses of tape.

[0121] The reinforcing thermoplastic materials used to form the wheel component can be associated to form an integral structure. As one example, a first reinforcing thermoplastic material can be used to form a rim base portion of the wheel component, and a second reinforcing thermoplastic material can be used to form a main structure portion of the wheel component. In certain examples, the first and / or second reinforcing thermoplastic materials can be in the form of a sheet, a tape, a panel, or other largely undefined or even partially flexible form. The reinforcing thermoplastic materials can undergo one or more processes to define the rim base portion and / or the main structure portion and / or other pieces of the wheel component or complex geometry component of the present disclosure. For example and as described in greater detail below, the reinforcing thermoplastic materials can be subjected to a stamping process in order to define a stamped form or other shape of the rim base portion, the main structure portion, and / or other portions of the wheel component. The stamp shape can generally define a specialized geometry of the rim base portion or the main structure portion, including a geometry suitable for use with a bicycle that includes an outer annular surface adapted to engage a bicycle tire and an inner annular surface configured to engage a series of spokes of the wheel component.

[0122] The heat bonding can be used to bond the rim base portion and the main structure portion to one another to form the wheel component as an integral structure. The integral structure can be a one-piece structure. In one example, the rim base portion and the main structure portion can generally be disposed in a mold or die that generally defines a target shape of the wheel component. The mold can be subjected to heat, including heat in excess of 450 degrees Fahrenheit; however, in other instances, the temperature can be higher or lower than 450 degrees Fahrenheit based on the particular composition of the reinforcing thermoplastic materials. Upon exposure to such heat, the thermoplastic materials soften and transition to a molten or partially molten state. The thermoplastic materials of each of the rim base portion and the main structure portion transition to this state within the mold, where the portions are generally adjacent or in contact with one another. For example, in the mold, such as in a mold compartment, the rim base portion and the main structure portion can be mechanically engaged with one another and / or pressed against one another’s surfaces. In this regard, upon transitioning to and becoming in the partially molten state, the reinforcing thermoplastic materials of each of the rim base portion and the main structure portion can generally bond with one another. For example, the thermoplastic material of the rim base portion and the thermoplastic material of the main structure portion can at least partially bond or mix as each approaches or enters the partially molten or fully molten state. As described herein, the reinforcing thermoplastic materials can subsequently be cooled, allowing each material to return to a more solidified state as a single, integrally formed component from the rim base portion and the main structure portion. For example, the reinforcing thermoplastic materials can be cooled to define the integral structure. This can allow the different components or portions of the rim (e.g., the rim base, the wall portion, etc.) to collectively define a one-piece, or continuous and / or seamless structure after formation.

[0123] The thermal bonding process can also be associated with defining a substantially hollow cavity within the wheel component. The wheel component can have a substantially hollow cavity to reduce weight and improve stability of the wheel. The wheel can also be formed as a substantially solid structure, such as can be the case in wheels used in jogging strollers, strollers, luggage, or other applications. Where the wheel component includes a substantially hollow cavity, the systems and techniques of the present disclosure include establishing and maintaining the shape of the cavity during the thermal bonding process. This allows the enhanced thermoplastic material to transition to and remain in a partially molten or molten state without collapsing or deforming in a manner that compromises the formation of the internal cavity. Maintaining the shape of the cavity can also facilitate bonding of the enhanced thermoplastic material, such as by allowing the rim base portion and the main structure portion to be pressed together with sufficient external force to facilitate general mixing or bonding of the various enhanced thermoplastic materials without such external force disrupting the shape of the cavity. Rather, with the shape of the cavity maintained, the external force of the mold can also facilitate formation of the shape of the cavity. For example, the rim base portion and / or the main structure portion can be pressed or manipulated against the sacrificial bladder, as one example, so as to use the partially molten or molten form of the enhanced thermoplastic material to establish the internal cavity shape of the wheel component.

[0124] In this regard, in some examples, a sacrificial bladder can be used to facilitate formation of an internal cavity of a wheel component during thermal bonding. For example, a substantially solid material including certain industrial foams and fillers or reinforcing materials can be shaped to define a profile of the internal cavity. Additionally or alternatively, an inflatable bladder can be used, such as a component that can maintain a pressurized region between the main structure portion and the rim base portion during the thermal bonding process. The rim base portion and the main structure portion can be associated with the sacrificial bladder within a mold assembly prior to thermal bonding. The sacrificial bladder can be substantially heat resistant and / or have a melting temperature that is higher or substantially higher than the heat to which the mold is subjected during the thermal bonding process. In this regard, the sacrificial bladder can maintain a solid shape, such as not melt or partially melt, while the enhanced thermoplastic material of the rim base portion and the main structure portion is melted or partially melted. Thus, as described herein, the rim base portion and the main structure portion can be bonded together without collapsing or deforming into the internal cavity defined by the respective portions. The rim base portion and the main structure portion can also be bonded together without inadvertently bonding to the sacrificial bladder.

[0125] After cooling, the sacrificial bladder can be removed from the wheel component, thereby defining a substantially hollow cavity within the wheel component. In the case where the wheel component is a section of a wheel, the sacrificial bladder can be removed from the side of the wheel component. Additionally or alternatively, the sacrificial bladder can be removed from a fully formed continuous and closed circular component. For example, it can be desirable for the sacrificial bladder to remain within the wheel section throughout the entire process of forming multiple wheel component sections to form a wheel component that can have a continuous unitary structure defining a circular shape. Further, the rim base portion and the main structure portion can be joined to one another as a continuous and closed circular component, thereby leaving the sacrificial bladder largely within the wheel component. In this regard, the sacrificial bladder can be removed via a port or hole, which can be machined through one or both of the rim base portion or the main structure portion. Subsequent operations can be used to cover or seal the port or hole and close the continuous circular cavity, which can be appropriate for a given application.

[0126] The described systems and techniques can also be adapted to maintain and / or establish an internal cavity without substantially using a sacrificial bladder. Broadly, the systems and techniques described herein can be used to pressurize the area of the mold compartment that holds the rim base portion and the main structure during the heat bonding process. For example, a fluid (e.g., compressed air) can be supplied to the area of the mold compartment substantially between the rim base portion and the main structure portion. As the reinforcing thermoplastic material bonds to one another, the fluid can act to maintain a cavity between the rim base portion and the main structure portion. For example, an inflatable component can partially extend into the cavity and supply compressed air, which can be supplied at a pressure of at least 40 psi, at least 100 psi, at least 200 psi, or greater based on the material properties of a given application. The compressed air can pressurize the mold compartment and at least partially hold the rim base portion and the main structure portion in a desired arrangement within the mold compartment. As the rim base portion and the main structure portion begin to transition to and become partially melted or melted, the pressure within the cavity can prevent the thermoplastic material from deforming in a manner that would hinder or detract from the profile of the internal cavity. For example, the reinforcing thermoplastic material that is partially melted or melted will be urged away from the pressurized area and toward the mold compartment boundaries and / or the respective rim base portion and main structure portion for heat bonding therebetween.

[0127] As described in greater detail herein, upon cooling, the inflation member can be removed from the internal cavity and the internal cavity can be substantially closed from the external environment. In some cases, this can involve the use of a plug or other thermoplastic material that can be reinforced so as to thermally bond with the rim base portion and / or the main structural portion upon exit of the inflation member from the wheel portion. Additionally or alternatively, the rim base portion and / or the main structural portion can be substantially self-sealing, allowing the entry point of the inflation member to substantially close upon itself when the inflation member is removed. In certain examples, this can be facilitated by the use of a high melt temperature film layered into one or both of the reinforcing thermoplastic material forming the rim base portion and / or the main structural portion. For example, in certain examples, a high melt temperature film can be layered into a mold shape of the reinforcement panel or the rim base portion or the main structural portion. The melt temperature of the film can be higher than the melt temperature of the associated rim base portion or main structural portion. In this regard, upon removal of the inflation member, the associated rim base portion or main structural portion cools and solidifies according to a different thermal profile than the film. For a given temperature, the film can exhibit a more solid state than the associated rim base portion or main structural portion. The film can act as an internal barrier that directs the reinforcing thermoplastic material along a path that closes and seals the entry point of the inflation member. In certain other examples, as described herein, the inflation member itself can be used to seal the entry point that delivers pressurized fluid into the cavity. For example, at least a portion of the inflation member can be formed from a material having a higher melt temperature than the melt temperature of the associated rim base portion or main structural portion. This portion can be a tip of the inflation member that is introduced into the cavity to supply pressurized air. The tip can be a consumable feature of the inflation member. For example, upon thermal bonding of the rim base portion and the main structural portion, the tip can be severed or otherwise removed from the remainder of the inflation member. The tip or consumable portion of the inflation member can in turn be used to seal the entry point of the pressurized air. For example, the tip exhibits a higher melt temperature than the associated rim base portion or main structural portion, and thus cools and solidifies according to a different thermal profile. This different thermal profile serves to direct the associated rim base portion or main structural portion to close and seal the entry point of the pressurized air.

[0128] Using these and other techniques described herein, the resulting wheel portion can include a substantially smooth exterior profile that can be free of indicia associated with the exit of a bladder from the internal cavity of the wheel portion. For example, the finished wheel portion can have an outer surface that can be free of holes having a lateral dimension greater than 20 mm and / or free of holes having a lateral dimension greater than 10 mm. As described herein, such holes can be an indication of bladder removal, while the absence of such holes can indicate a streamlined, bladderless manufacture of the hollow cavity.

[0129] It should be understood that while the foregoing discussion includes references to wheel components and other features related to bicycles, it is presented herein as an exemplary implementation of systems and techniques for forming complex and optionally hollow structures entirely from one or more reinforced thermoplastic materials. These systems and techniques provide significant improvements over existing bicycle-related technology, for example, by improving the strength-to-weight ratio, by increasing the pull strength capacity of the rim, by accommodating the difference between compressive and tensile stresses in the rim, and other improvements not realized by existing designs. As contemplated herein, the entirely reinforced thermoplastic components can be applicable to a variety of structures and industries requiring high performance. In some cases, this can include adapting the reinforced thermoplastic materials to other wheel-related applications, including wheel applications for strollers, carts, luggage, and other uses. For example, the reinforced thermoplastic materials can be used to form a wheel having an integrally formed tri-spoke shape, which can optionally have an internal cavity. Other uses are contemplated, including using the reinforced thermoplastic materials for applications having aerodynamic-specific shape requirements, such as, for example, a blade for a wind turbine or a hydrodynamic foil. Such applications can benefit from a sufficiently high strength-to-weight ratio and often require the precise external profile that the technology of the present disclosure can provide. In other examples, other applications are contemplated within the scope of the present disclosure.

[0130] Reference will now be made to the drawings, which facilitate explanation of various features of the present disclosure. The following description presents the description in terms of illustrative embodiments for the purpose of description and description. Furthermore, the description is not intended to limit the inventive aspects to the form disclosed herein. Consequently, variations and modifications commensurate in skill and knowledge with the teachings presented herein are within the scope of the inventive aspects.

[0131] As described herein, the reinforced thermoplastic structures can be adapted for use with a bicycle or other device that uses a wheel. In this regard, Figure 26 A bicycle 100 is depicted. The bicycle 100 includes a wheel assembly 108 having a rim 112. The rim 112 can be formed from a reinforced thermoplastic material, such as the reinforced thermoplastic materials discussed generally above and described in greater detail below. The rim 112 can be adapted to withstand dynamic conditions during use of the bicycle 100 by a rider, including compressive and tensile stresses at particular local regions of the rim 112.

[0132] As Figure 27AThe composite rim 112 is shown engaged with a tire 116. The tire 116 can be any suitable component configured to engage and grip a riding surface to facilitate forward motion of the bicycle 100, including an elongated profile tire. As described in greater detail below, the tire 116 can induce various maximum compressive stresses on the rim 112. The rim 112 is associated with a series of spokes 114 that structurally connect the rim 112 to other components of the bicycle 100. The series of spokes 114 can induce various maximum stresses on the rim 112.

[0133] In Figure 27B non-limiting examples, the wheel assembly 108 and the rim 112 are shown with a bicycle 100. However, it should be appreciated that the rim 112 can be used with various bicycles and / or any suitable device that implements wheel movement. This can include bicycles with electric motors, strollers, carts, luggage, etc. For illustrative purposes, the bicycle 100 is further shown as having a frame 104, a front fork 120, a handlebar assembly 124, a drive assembly 126, pedals 128, a chain 132, a saddle 136, and a seat post 140. It should be noted that the bicycle 100 can include other components (or variations of the aforementioned components), such as various derailleurs, heat devices, cassettes, brakes, various structural frame tubes, etc. Accordingly, the discussion of any bicycle (such as the bicycle 100) is merely illustrative.

[0134] With reference to Figure 27A Detail 1-1 of the wheel assembly 108 is shown. Figure 27A The rim 112 is shown connected with the series of spokes 114 and engaged with the tire 116. The tire 116 is shown as contacting a riding surface 101. The rim 112 is subjected to various dynamic conditions during use of the bicycle 100. The location of forces received by the rim 112 changes as the wheel assembly 108 rotates, and the distribution of forces can also be different.

[0135] In Figure 28 Detail 1-2, the rim 112 is shown as being subjected to a compressive force F C and a tensile force F T . For example, the compressive force F C may result from engagement of the tire 116 with the riding surface 101. The tensile force F T may result from structural engagement of the series of spokes 114 with other components of the bicycle 100. In other examples, the rim 112 is subjected to other forces that can vary based on dynamic operating conditions of the bicycle 100.

[0136] The rim 112 is formed entirely of a reinforced thermoplastic material, such as any of the reinforced thermoplastic materials described herein. The reinforced thermoplastic material can be particularly adapted to increase the strength to weight ratio of the rim 112. This can enhance the performance of the rim not only by reducing the overall weight of the wheel assembly 108, but also by selectively providing strength to the rim 112 in targeted areas. For example, during use of the bicycle 100, a series of spokes 114 exert various forces on the rim 112. In one example, the rim 112 is adapted via the reinforced thermoplastic material to withstand the tensile forces of the spokes 114 from one or more of the series of spokes for high performance operation. Tensile force can indicate the amount of force exerted by a spoke on a portion of the rim bed, such as the portion where the spoke and the rim 112 combine. For example, the rim 112 can be adapted to withstand a tensile force of at least 300 pounds from a spoke in the series of spokes 114, at least 400 pounds from a spoke in the series of spokes 114, at least 500 pounds from a spoke in the series of spokes 114, or more.

[0137] Figure 29 A rim 300 formed entirely of a reinforced thermoplastic material is depicted. The rim 300 can be a unitary structure having a continuous circular profile 301. The rim 300 can also be substantially hollow throughout the continuous circular cavity. The rim 300 can also have a substantially smooth, seamless exterior surface that is substantially free of any indicia or other evidence of intermediate manufacturing processes from the interior cavity. Such features cooperate to define an aesthetically pleasing finish of the rim 300. Additionally, these features can reduce potential failure mechanisms by providing a seamless finish reinforced by fibers of the reinforced thermoplastic material.

[0138] The rim 300 can include a rim bed portion 304 and a main structure portion 310. The rim bed portion 304 and the main structure portion 310 can define a unitary structure. For example, the rim bed portion 304 and the main structure portion 310 can collectively define a one-piece, continuous, and / or seamless structure after formation. The rim bed portion 304 is generally configured to engage a bicycle tire. For example, the rim bed portion 304 can define an outer annular surface 306 adapted to receive and retain a bicycle tire. The main structure portion 310 is generally configured to define a channel of the rim 300 and is adapted to engage a series of spokes. For example, the main structure portion 310 can define an inner annular surface 312 adapted to engage a series of spokes 390. The series of spokes 390 can be connected to a hub 392 or other feature. In this regard, the series of spokes 390 can exhibit tensile forces on the main structure portion 310. In certain examples, the main structure portion 310 can define a reinforced region 314 where the series of spokes 390 and the main structure 310 engage one another. The reinforced region 314 can be formed of additional reinforced thermoplastic material, selectively providing increased strength and performance.

[0139] As shown in detail view Figure 30 , the wheel well portion 304 and the main structure portion 310, while cooperating to define the integrally formed wheel 300, can be provided as two separate components during the manufacturing process. The wheel well portion 304 and the main structure portion 310 can be thermally bonded to one another generally along the thermal bond interface 308. For purposes of illustration, the thermal bond interface 308 is shown in detail. However, it should be appreciated that while the wheel well portion 304 and the main structure portion 310 are provided as separate components during the manufacturing process, the thermal bond interface 308 can be substantially invisible to the naked eye in the final product, and thus, defines a seamless interface or transition between the wheel well portion 304 and the main structure portion 310. In this regard, the final wheel 300 can have a seamless surface 302. Figure 31

[0140] Figure 32 A cross-sectional view of the wheel 300 of Figure 1 is depicted taken along line 3B-3B. More specifically, Figure 1 a cross-sectional view of a reinforced thermoplastic material used to form the wheel 300 is shown. The wheel 300 can be formed entirely of the reinforced thermoplastic material. In this regard, the wheel well portion 304, the main structure portion 310, and / or any or all other portions of the wheel 300 can be formed of the reinforced thermoplastic material. It should thus be appreciated that the following discussion of the reinforced thermoplastic material can apply to any or all components of the wheel 300, or more generally, to the wheel components and complex geometries described herein.

[0141] Figure 1 A cross-section of the wheel 300 formed of the reinforced thermoplastic material 350 is shown. The reinforced thermoplastic material 350 broadly includes reinforcing fibers 354 disposed in a thermoplastic material 358. The thermoplastic material 358 is generally defined as a material that softens upon heating and hardens upon cooling in opposition. The thermoplastic material 358 can be heated and cooled continuously multiple times without a significant reduction in material performance. Certain resins, polymers, synthetic materials, nylons, and / or other materials can be used. The reinforcing fibers 354 provide strength to the thermoplastic material 358. For example, the fibers 354 can maintain shape and physical state during heating of the thermoplastic material 358. Sample fibers include carbon fibers, glass fibers, Kevlar fibers, basalt fibers, and / or other suitable materials adapted to provide strength to the thermoplastic material 358. In some cases, as shown in detail Figure 2 , the fibers 354 can be individually or collectively wrapped or partially wrapped in a coating 356. The coating 356 can be a nanocoating that defines a barrier between the fibers 354 and the thermoplastic material 358.

[0142] ​The reinforced thermoplastic material 350 can be manufactured in a variety of ways to increase the strength of the material through the arrangement of the fibers 354. For example, in some cases, the fibers 354 can be subjected to a spreading technique that establishes the fibers 354 as spread tows in the thermoplastic material 358. In some cases, this can allow a given cross-section of the reinforced thermoplastic material 350 to have a width 370 that is greater than the height 368. Additionally or alternatively, the spreading technique or other manufacturing technique can arrange the fibers 354 in an elongated manner. For example, the fibers 354 can generally be arranged substantially parallel to one another and elongated. Additionally or alternatively, the fibers 354 can define a compact arrangement 362 in the thermoplastic material 358. The compact arrangement 362 can help to organize the fibers 354 in a manner that increases the volumetric density of the fibers 354 in the reinforced thermoplastic material 350. For example, for a representative volume 366 of the reinforced thermoplastic material 350, the fibers 354 can define at least 40% of the volume of the material 350, at least 70% of the volume of the material 350, or other suitable value based on the target strength and application.

[0143] Figure 2 Sample structures of wheel components of the present application are depicted. The wheel components can be segments of a wheel or continuous circular components. Figure 2 Various cross-sectional views of wheel components are depicted. Figure 3A The wheel components of the present application can be used to define any of the wheel rims and wheel assemblies described herein, including Figure 3A and 2 the wheel rim 112 of Figure 3A and 3B the wheel rim 300. Furthermore, it should be understood that Figure 3B A wheel component is shown in a state prior to thermal bonding for illustrative structural relationships of the reinforced thermoplastic materials used to form the wheel component. After a thermal bonding process, such as any of the thermal bonding processes described herein, the individual reinforced thermoplastic materials can be connected to one another in a manner that forms the wheel component as a single, integrally formed structure.

[0144] Referring to Figure 3A , a cross-sectional view of a wheel component 400 is shown. The wheel component 400 can be formed entirely of a reinforced thermoplastic material, such as any of the reinforced thermoplastic materials described herein, for which redundant explanations are omitted here for the sake of clarity.

[0145] The wheel component 400 is in Figure 3BThe wheel component 400 is shown to include a rim base portion 404 and a main structure portion 410. The rim base portion 404 and the main structure portion 410 cooperate to define a cavity 406. The rim base portion 404 can define an outer annular surface 408 adapted to engage a bicycle tire. The main structure portion 410 can define an inner annular surface 414 adapted to engage a series of spokes. The main structure portion 410 can optionally define a reinforcement region 416 along some or all of the inner annular surface 414. The reinforcement region 416 can be a region of increased strength of the main structure portion to facilitate increased strength of the wheel component 400, for example, to provide a high enough tensile strength for high performance use, as described herein.

[0146] The main structure portion 410 can include a first wall portion 412a and a second wall portion 412b. In Figure 3B some examples, the first wall portion 412a and the second wall portion 412b are provided as generally unitary forms of reinforced thermoplastic material. The first and second wall portions 412a, 412b can have a thickness 492. In some cases, the thickness 492 can be less than a thickness 490 of the rim base portion 404; however, this is not required. The main structure portion 410 and the rim base portion 404 can be connected to one another at an edge junction. In Figure 3B some arrangements, the main structure portion 410 and the rim base portion 404 can collectively define a thickness 494 at the edge junction. This increased thickness can provide stability for a bicycle tire engaged with the rim base portion 404.

[0147] Referring to Figure 4-6 , a cross-sectional view of a wheel component 500 is shown. The wheel component 500 can be formed entirely of reinforced thermoplastic material, such as any of the reinforced thermoplastic materials described herein, for which redundant explanations are omitted here for the sake of clarity. The wheel component 500 can be substantially similar to the wheel component 400 of Figure 4-6 and include a rim base portion 504, a main structure portion 510, a cavity 506, an outer annular surface 508, an inner annular surface 514, a first wall portion 512a, a second wall portion 512b, a reinforcement region 516, a thickness 592, a thickness 590, and a thickness 594, for which redundant explanations are omitted here for the sake of clarity.

[0148] Figure 4-6 The first wall portion 512a and the second wall portion 512b are further shown to be defined by different pieces of reinforced thermoplastic material. The first wall portion 512a and the second wall portion 512b can define an overlap 530 at the reinforcement region 516. The overlap 530 of the first wall portion 512a and the second wall portion 512b can reinforce the strength of the wheel component 500 at the inner annular surface 514.

[0149] Also as Figure 1As shown, the first wall portion 512a and the rim base portion 504 can be connected to one another along a first ridge region 580. For example, the first wall portion 512a can have an end 572 and the rim base portion 504 can have an end 570. The ends 570, 572 can be connected to one another using the techniques described herein to form the first ridge region 580. Further, the second wall portion 512b and the rim base portion 504 can be connected to one another along a second ridge region 582. For example, the second wall portion 512b can have an end 573 and the rim base portion 504 can have an end 571. The ends 571, 573 can be connected to one another using the techniques described herein to form the second ridge region 582. The first and second ridge regions can cooperate to receive a bicycle tire therebetween. In Figure 3A In embodiments, the ends 570, 572 are arranged substantially parallel to one another, and an end point of each of the respective ends 570, 572 is substantially unobstructed by the respective one of the first wall portion 512a or the rim base portion 504. Further, the ends 571, 573 are arranged substantially parallel to one another, and an end point of each of the respective ends 571, 573 is substantially unobstructed by the respective one of the second wall portion 512b or the rim base portion 504.

[0150] In some cases, the ends 570, 571 of the rim base portion 504 can be wrapped around the respective ends of the first and second wall portions. For example and with reference to Figure 4-6 the end 570 of the rim base portion 504 is at least partially wrapped around the end 572 of the first wall portion 512a. As Figure 4 further shown in FIG. 5B, the end 571 of the rim base portion 504 is at least partially wrapped around the end 573 of the second wall portion 512b. Thus, the at least partial wrapping can help modify the performance characteristics of the first and second ridge regions 580, 582, such as to enhance the strength of these regions or otherwise tailor the regions for a particular application.

[0151] In some cases, the ends 572, 573 can be wrapped around the respective ends of the rim base portion 504. For example and with reference to Figure 4 the end 572 of the first wall portion 512a is at least partially wrapped around the end 570 of the rim base portion 504. As Figure 4 further shown in FIG. 5B, the end 573 of the second wall portion 512b is at least partially wrapped around the end 571 of the rim base portion 504. Thus, the at least partial wrapping can help modify the performance characteristics of the first and second ridge regions 580, 582, such as to enhance the strength of these regions or otherwise tailor the regions for a particular application.

[0152] With reference to Figure 4FIG. 6 shows a cross-sectional view of a wheel component 600. The wheel component 600 can be formed entirely of a reinforced thermoplastic material, such as any of the reinforced thermoplastic materials described herein, for which redundant explanations are omitted here for the sake of clarity. The wheel component 600 can be substantially similar to the wheel component 400 of Figure 5A and include a rim base portion 604, a main structural portion 610, a cavity 606, an outer annular surface 608, an inner annular surface 614, a first wall portion 612a, a second wall portion 612b, a reinforced region 616, an overlap 630, a first ridge region 680, an end 670, an end 672, a second ridge region 682, an end 671, an end 673, a thickness 692, a thickness 690, and a thickness 694, for which redundant explanations are omitted here for the sake of clarity.

[0153] Despite the foregoing similarities, the rim base portion 604 is shown in Figure 4 as including a first rim base portion 604a and a second rim base portion 604b. The first and second rim base portions 604a, 604b can be layered or composite components or layers formed with one another to define the rim base portion 604. Figure 5A The dual-layer configuration of the rim base portion 604 can help reinforce the outer annular surface 608. The thickness 690 can be defined as the thickness including the first rim base portion 604a and the second rim base portion 604b.

[0154] Figure 5A Various operations of manufacturing shaped forms of reinforced thermoplastic materials are depicted. Reinforced thermoplastic materials can initially be manufactured as sheets, rolls, tapes, panels, etc. According to the techniques described herein, the reinforced thermoplastic materials can be manipulated into shapes that are subsequently used to form wheel components or other complex geometries. For example, the reinforced thermoplastic materials can be stamped or pressed into shapes to define a rim base portion, a main structural portion, one or more wall portions, one or more reinforced portions, etc. The stamped formed shapes of these components can then be mechanically joined to one another and subjected to a thermal bonding process to form a continuous, integrally formed circular structure of a wheel component.

[0155] Referring to Figure 5A , operations 700a are shown. At operation 700a, an impression shape of a sample rim base portion can be formed. For example, a reinforced thermoplastic material 708 can be disposed substantially between a first impression half 704 and a second impression half 706. The reinforced thermoplastic material 708 can be substantially similar to any of the reinforced thermoplastic materials described herein, for which redundant explanations are omitted here for the sake of clarity. The first and second impression halves 704, 706 can be advanced toward the reinforced thermoplastic material 708 so as to press the reinforced thermoplastic material 708 into the shape of a rim base portion, such as the rim base portion 604 of FIG. 6. Figure 5BThe reinforced thermoplastic material 708 can be heated to facilitate deformation into the mold shape defined by the first and second mold halves 704, 706. For ease of explanation, the reinforced thermoplastic material 708 can be heated to facilitate deformation into the mold shape shown in FIG. 7A.

[0156] Referring to FIG. 7B, operations 700b are illustrated. At operation 700b, a mold shape of a sample wall portion can be formed. For example, a reinforced thermoplastic material 718 can be disposed substantially between a first mold half 714 and a second mold half 716. The reinforced thermoplastic material 718 can be substantially similar to any of the reinforced thermoplastic materials described herein, redundant explanations of which are omitted here for the sake of clarity. The first and second mold halves 714, 716 can be advanced toward the reinforced thermoplastic material 718 so as to press the reinforced thermoplastic material 718 into the shape of a wall portion, such as the shape shown in FIG. 7B. For ease of explanation, the reinforced thermoplastic material 718 can be heated to facilitate deformation into the mold shape defined by the first and second mold halves 714, 716.

[0157] Referring to FIG. 7C, operations 700c are illustrated. At operation 700c, a mold shape of another sample wall portion can be formed. For example, a reinforced thermoplastic material 728 can be disposed substantially between a first mold half 724 and a second mold half 726. The reinforced thermoplastic material 728 can be substantially similar to any of the reinforced thermoplastic materials described herein, redundant explanations of which are omitted here for the sake of clarity. The first and second mold halves 724, 726 can be advanced toward the reinforced thermoplastic material 728 so as to press the reinforced thermoplastic material 728 into the shape of a wall portion, such as the shape shown in FIG. 7C, which can be a wall portion configured to correspondingly engage the wall portion of FIG. 7B. For ease of explanation, the reinforced thermoplastic material 728 can be heated to facilitate deformation into the mold shape defined by the first and second mold halves 724, 726.

[0158] In certain instances, a film can be laid up to the reinforced thermoplastic material to facilitate thermal bonding. For example, a film having a higher melting temperature than the reinforced thermoplastic material can be laid up into the mold shape of one or more portions of a wheel component and / or a reinforcement panel. The different thermal properties of the film can affect the behavior of the reinforced thermoplastic material as it begins to cool. For example and as described herein, the reinforced thermoplastic material can be affected to seal or close a hole formed through the material, such as a hole for providing pressurized air to an interior cavity.

[0159] For illustrative purposes, Figure 5BAn arrangement 750 is shown having a film 754 applied to a mold shape 762. The mold shape 762 can be or define a portion of a rim base portion or a main structural portion described herein. The mold shape 762 can define a contour 766. The film 764 can be arranged to match the contour 766, thus assuming the contour 758 when layered with the mold 762.

[0160] Figure 5C An arrangement 780 is shown having a film 784 and a reinforcement panel 792. The reinforcement panel 792 can be a reinforced thermoplastic material that can be provided in a state prior to stamping one or more components of various wheel assemblies described herein. The reinforcement panel 792 can define a contour 796, which in some cases can be substantially planar. The film 784 can be arranged to match the contour 796, thus assuming the contour 788 when layered with the reinforcement panel 792. The layered reinforcement panel 792 and film 784 can in turn be introduced to a mold or die to form one or more components of a wheel assembly as an optional laminated structure having a reinforced thermoplastic material and a higher melting temperature film layered.

[0161] In some cases, the reinforced thermoplastic material can be formed from a plurality of plies. The plies can be arranged relative to one another to define a laminate or composite structure that can be used to form one or more portions of a wheel component. As one example, a wall portion of a wheel component can be formed from a plurality of plies of thermoplastic material. The plurality of plies can be arranged to overlap one another and collectively form a radial pattern to define the wall portion. One or more or all of the plurality of plies can be arranged or offset relative to a central axis of the wheel component. For example, a given ply can have an edge that defines an angle with the central axis of between approximately 22.5 and 75 degrees, such as approximately between 40 and 60 degrees, such as preferably about 45 degrees. The offset angle can be adjusted to optimize wall strength of the wall portion.

[0162] Turning to Figure 5C An arrangement 800 is shown for forming a reinforced thermoplastic material from a plurality of plies. The arrangement 800 includes a radial pattern of plies 802. The radial pattern of plies 802 is arranged about a wall portion contour 804. The wall portion contour 804 can generally indicate a circular shape of a wheel component. In other examples, other contours and shapes can be used to arrange the plurality of plies. The wall portion contour 804 is shown having a center 806. The center 806 can define a central axis of the wall portion contour 804 and / or other generally circular components of a wheel component that include an outer annular surface.

[0163] The radial pattern of plies 802 is arranged about the wall portion contour 804 in a manner that collectively defines a wall portion 808. The wall portion 808 can be a portion of a wheel component, such as a rim base portion or a main structural portion described herein. The wall portion 808 is shown having a center 810. The center 810 can define a central axis of the wall portion 808 and / or other generally circular components of a wheel component that include an outer annular surface. Figure 6The image shows a first fabric layer 810 and a second fabric layer 820. The first fabric layer 810 includes a first edge 812. The second fabric layer 820 includes a second edge 822. The first edge 812 may define an angle θ1 with a central axis defined by a center 806. The second edge 822 may define an angle θ2 with the central axis defined by the center 806. Figure 4 In the example, angles θ1 and θ2 are shown as approximately 45 degrees. Angles θ1 and θ2 can define the deflection or orientation of the fabric layers 810 and 820. Angles θ1 and θ2 can be adjusted to optimize the wall strength of the wheel components, for example, to a degree value substantially between 22.5 and 75 degrees (e.g., substantially between 40 and 60 degrees).

[0164] exist Figure 6 In the example, the first fabric layer 810 and the second fabric layer 820 may be substantially rectangular structures. The first and second fabric layers 810, 820 may overlap each other to form a cross pattern, wherein a second edge 822 extends over and across the first edge 812. The first and second fabric layers 810, 820 together may define an arrangement or grouping of fabric layers. In this respect, the radial pattern of the fabric layer 802 may include multiple arrangements of the fabric layers 810, 820 to define radially cross fabric layers. Multiple arrangements of fabric layers may be grouped together and stacked on top of each other to define a wall portion. For example, according to an exemplary description, the wall portion may include multiple layers of cross fabric layer stacks, including 6 layers of cross fabric layer stacks, having 12, 22 or more overlapping strip layers.

[0165] For example, and such Figure 6 As shown, wall portion 850 is shown as being composed of Figure 7A-7E The layers 800 are formed. For example, the radial patterns of the cord layers 802 can be laid together to form a composite structure. The composite structure with radially intersecting cord layer patterns can be formed or shaped as part of a continuous wheel component, for example, as a wall portion. As described throughout, sample forming techniques include stamping, pressing, molding, thermoforming, etc. Figure 7A It is shown that has a wall portion 850 Figure 7A The composite material has a radially interlaced fabric layer pattern. In the shape of the formed wall portion 850, the first edge 812 and the second edge 822 can maintain deflection angles θ1, θ2 (e.g., maintaining a value of approximately 45 degrees), thereby enhancing the wall strength of the component. As mentioned above, the deflection angle can range from a value substantially between 22.5 and 75 degrees, for example, substantially between 40 and 60 degrees, etc.

[0166] Turning Figure 7D This shows several other example stacks of reinforced thermoplastic parts. Figure 7E The laminated structure can be used to form the wall portion of the wheel component, which is essentially similar to the structure described above.Figure 8A and 8B The described ply 800. As shown, the shape, orientation, and number of plies used to form the wall portion of the wheel component can vary to provide different structural properties, geometries, and / or surface finishes. Figure 8A

[0167] Referring to Figure 8A , a first ply 900a is shown. The first ply 900a includes a radial pattern of plies 910a. The radial pattern of plies 910a is arranged along a wall portion profile 902. The wall portion profile 902 can define a center 906. The radial pattern of plies 910a can include a ply 912a having a first end 914a, a second end 916a, and an edge 918a. The edge 918a can define an angle of bias Θ 9a In Figure 8A examples, the first end 914a and the second end 916a can be different. For example, the first end 914a can be oriented substantially transverse to the edge 918a, and the second end 916 can extend from the edge 918a at an angle greater than 90 degrees. The radial pattern of plies 910a is disposed around a wall portion overlap such that the ends of the respective plies abut one another to define and complete the radial cross-ply pattern.

[0168] Referring to Figure 8B , a second ply 900b is shown. The second ply 900b includes a radial pattern of plies 910b. The radial pattern of plies 910b is arranged along a wall portion profile 902. The wall portion profile 902 can define a center 906. The radial pattern of plies 910b can include a ply 912b having a first end 914b, a second end 916b, and an edge 918b. The edge 918b can define an angle of bias Θ 9b In Figure 8A examples, the ply 912b can be rotated relative to the ply above or below the ply 912b. For example, the ply 912b can be rotated to overlap the abutting connection of the ply below. In this regard, the ply 192b can be rotated to establish a desired connection with the ply below to further adjust the wall strength of the wheel component.

[0169] Referring to Figure 8B , a third ply 900c is shown. The third ply 900c includes a radial pattern of plies 910c. The radial pattern of plies 910c is arranged along a wall portion profile 902. The wall portion profile 902 can define a center 906. The radial pattern of plies 910c can include a ply 912c having a first end 914c, a second end 916c, and an edge 918c. The edge 918c can define an angle of bias Θ​9c In the example of FIG. 9c, the first end 914c can be substantially similar to the second end 914b. For example, the first and second ends 914a, 914b can be mirror images of one another, and each can extend in substantially opposite directions and at an angle greater than 90 degrees from the edge 918c. In this regard, the plies 912c can be manipulated to establish a desired connection or overlap to an underlying adjacent ply, further adjusting the wall strength of the wheel component.

[0170] Referring to Figure 8A , a fourth ply stack 900d is shown. The fourth ply stack 900d includes a radial pattern of plies 910d. The radial pattern of plies 910d is arranged along a wall portion profile 902. The wall portion profile 902 can define a center 906. The radial pattern of plies 910d can include a ply 912d having a first end 914d, a second end 916d, and an edge 918d. The edge 918d can define an angle of bias Θ 9d In the example of FIG. 9c, the first end 914c can be substantially similar to the second end 914b. For example, the first and second ends 914a, 914b can be mirror images of one another, and each can extend in substantially opposite directions and at an angle greater than 90 degrees from the edge 918c. In this regard, the plies 912c can be manipulated to establish a desired connection or overlap to an underlying adjacent ply, further adjusting the wall strength of the wheel component. Figure 9A-9D In the example of FIG. 9c, the first end 914c can be substantially similar to the second end 914b. For example, the first and second ends 914a, 914b can be mirror images of one another, and each can extend in substantially opposite directions and at an angle greater than 90 degrees from the edge 918c. In this regard, the plies 912c can be manipulated to establish a desired connection or overlap to an underlying adjacent ply, further adjusting the wall strength of the wheel component. Figure 9A-9D In the example of FIG. 9c, the first end 914c can be substantially similar to the second end 914b. For example, the first and second ends 914a, 914b can be mirror images of one another, and each can extend in substantially opposite directions and at an angle greater than 90 degrees from the edge 918c. In this regard, the plies 912c can be manipulated to establish a desired connection or overlap to an underlying adjacent ply, further adjusting the wall strength of the wheel component. Figure 8A While various ply stack strategies and configurations are shown, any additional configurations and / or combinations of the shown ply stack strategies can be used to form a reinforced thermoplastic material from a plurality of plies.

[0171] Figure 9A-9D A sample wheel component 1000 prior to thermal bonding is depicted. The wheel component 1000 can be substantially similar to the various wheel components described herein and includes a cavity 1001, a rim base portion 1004, an outer annular surface 1008, a main structural portion 1010, a first wall portion 10112a, a second wall portion 12b, and an inner annular surface, the redundant explanation of which is omitted here for the sake of clarity.

[0172] Figure 9AThe first wall portion 1012a is also shown defining an engagement feature 1013a and the second wall portion 1012b is shown defining an engagement feature 1013b. The engagement features 1013a, 1013b generally overlap one another at the inner annular surface 1014. In this regard, the engagement features 1013a, 1013b can define a reinforced region of the wheel component 1000 along which the wheel component 1000 can be adapted to receive a series of spokes. Figure 9A A sacrificial material 1020 is also shown. The sacrificial material 1020 can help define the shape of the cavity 1001 during a thermal bonding process. The rim base portion 1004, the first wall portion 1012a, the second wall portion 1012b, and the sacrificial material 1020 are shown mechanically engaged with one another and generally define a loose fit connection. In this configuration, the collection of components can be associated with a mold in which they can be subjected to heat in order to form a thermal bond between the various reinforced thermoplastic materials.

[0173] In this regard, Figure 9B The wheel component 1000 is shown associated within a mold 1030. Generally, as Figure 9B shown, the wheel component 1000 can be arranged with a mold compartment 1040. The mold 1030 can be subjected to heat to transition the reinforced thermoplastic materials to a partially molten or molten state in which they can thermally bond with one another. For example, in some cases, the mold 1030 can be subjected to a temperature of at least 400 degrees Fahrenheit, at least 450 degrees Fahrenheit, at least 500 degrees Fahrenheit, or other temperature to transition the reinforced thermoplastic materials to a partially molten or molten state, which can be based on the particular material properties of the thermoplastic materials.

[0174] The mold 1030 operates to maintain and hold the various pieces of the wheel component 1000 relative to one another during thermal bonding. For example, the mold 1030 can include a first plate 1032a, a second plate 1032b, and a third plate 1032c. The plates 1032a, 1032b, 1032c can cooperate to enclose the wheel component 1000 within the mold 1030. While the plates 1032a, 1032b, 1032c are shown as segments of a circular feature, it should be understood that the plates 1032a, 1032b, 1032c can be continuous circular components (as shown by the dashed lines in Figure 9C the first plate 1032a can have a profile that engages the first wall portion 1012a, the second plate 1032b can have a profile 1036 configured to engage the second wall portion 1012b, and the third plate 1032c can have a profile 1038 adapted to engage the rim base portion 1004.

[0175] As described herein, Figure 9DThe sacrificial material 1020 helps maintain the shape of the cavity of the wheel component 1000 during thermal bonding. Figure 9D and 11 Examples of the present disclosure are shown in which pressurized fluid is used and the shape of the interior cavity of the wheel component is maintained during thermal bonding without a bladder. For example, an inflation component can be used to deliver pressurized fluid to a region of the mold defining the interior cavity of the wheel component. The inflation component can be removed after thermal bonding. In some cases, the reinforced thermoplastic material can enclose and self-seal and / or be adapted to enclose with other reinforced thermoplastic components, such as a portion of the inflation component formed from the reinforced thermoplastic material.

[0176] In this regard, Figure 9D and 11 A wheel component 1080 is shown generally disposed within a mold 1050. The wheel component 1080 and the mold 1050 can be substantially similar to the wheel components and molds described with respect to Figure 9A-9D and 10B and include a rim base portion 1084, a first wall portion 1082a, a second wall portion 1082b, a first plate 1052a, a second plate 1052b, a third plate 1052c, a profile 1058, and a profile 1056.

[0177] The mold 1050 can also be adapted to provide pressurized fluid to the wheel component 1080 during thermal bonding. In this regard, Figure 10A The mold 1050 is shown including an inflation component 1070. The inflation component 1070 can include an inlet 1072 adapted to receive pressurized fluid, such as compressed air, from a source. The inflation component 1070 can also include a tip 1074. The tip 1074 can be inserted into the mold compartment 1060 so as to direct pressurized air to a region substantially between the pieces of the wheel component 1080. For example, the inflation component 1070 can generally extend through the third plate 1052c such that the tip 1074 is advanced through the rim base portion 1084 at the opening 1085. The inflation component 1070 can be configured to deliver pressurized air to the mold compartment 1060 of at least 40 psi or at least 100 psi or at least 200 psi, and / or at higher pressures, each of which can be adjusted to mitigate deformation of the reinforced thermoplastic material into the cavity. To facilitate the foregoing, the inflation component 1070 can also be associated with an adapter 1087. The adapter 1087 can be associated with the tip 1074 via an O-ring 1086 or other sealing structure. As Figure 10AAs shown, the adapter 1087 can fit at least partially into a cavity of the wheel component 1080 to facilitate pressurized fluid input into the interior cavity and to minimize leakage. After the thermally bonding the reinforced thermoplastic material, the mold 1050 can be allowed to cool and / or undergo an active cooling process. The pneumatic component 1070 can be removed from the wheel component 1080, and the hole 1085 can be closed. Many mechanisms are possible and described herein. For example, the reinforced thermoplastic material can be configured to be substantially self-sealing for the hole 1085. This can be facilitated by a higher melting temperature film that can be laid up to the mold shape of the wheel component and / or reinforcement panel. In other cases, a separate plug, patch, or reinforcement strip can be used to close the hole 1085, which can also be formed of reinforced thermoplastic material. This material can cool together in a seamless manner, in a manner that closes the hole 1085, leaving substantially no visible indication of the hole 1085 in the finished product. In this regard, the wheel well portion 1084 and / or the main structure portion 1082 can be formed entirely as a reinforced thermoplastic component with a continuous hollow cavity and without surface indicia of the manufacturing process associated with the bladder exit.

[0178] In certain other cases, the pneumatic component 1070 can be used to seal a hole or other entry point of pressurized air into the cavity. For example, Figure 10A and 13 A wheel component 1200 is shown, which can have an interior cavity pressurized by a pneumatic component 1250. The wheel component 1200 and the pneumatic component 1250 can be substantially similar to the wheel component 1000 and the pneumatic component 1120 of Figure 10B and include a main structure portion 1204, a first wall portion 1208a, a second wall portion 1208b, a hole 1206, a cavity 1210, an inlet or shaft portion 1254, and a tip 1258. As shown, Figure 10A The pneumatic component 1250 can deliver pressurized air into the cavity 1210 via the tip 1258. For example, the tip 1258 can have a conduit 1262 that allows compressed air to flow into the cavity 1210.

[0179] A portion of the inflatable member 1250, such as the tip 1262, can be a consumable member for sealing the hole 1206. For example, the tip 1262 can be formed of a thermoplastic material, which can or can not be reinforced, and / or other material that generally has a higher melt temperature than the reinforced thermoplastic material used to form the rim base portion 1204 and / or the first or second wall portions 1208a, 1208b. After the portions of the wheel member 1200 are heat bonded, the tip 1262 can be severed from the shaft 1254. The tip 1262 can remain partially bonded with the rim base portion 1204, such as with the hole 1206 and for sealing and plugging the hole 1206. For example, the tip 1262 can cool according to different thermal properties than the rim base portion 1204 surrounding. Using the tip 1262 to plug or obstruct the hole 1206, this difference can cause the rim base portion 1204 to at least partially close on itself and seal the hole 1206. The cavity 1210 can thus be sealed from the external environment. The self-sealing properties of the rim base portion 1204 in cooperation with the tip 1262 can define a substantially smooth, seamless outer surface of the wheel member.

[0180] As described above, the pieces of any of the wheel members described herein can be heat bonded to one another to form a continuous circular segment. Additionally or alternatively, the pieces of a wheel member can be heat bonded to one another to form a continuous circular shape. Figure 10B An example mold 1400 for heat bonding pieces of a wheel member into a continuous circular shape is depicted. In this regard, it should be understood that the molds described with reference to FIGS. 9 and 10 can be or can be adapted to define a continuous circular mold 1400. Figure 10B The continuous circular mold 1400 presented in FIG. 14.

[0181] Generally speaking, Figure 10C The mold 1400 is shown to include a first plate 1408a and a second plate 1408b. The mold 1400 also includes a set of annular members 1412. The pieces of the wheel member are generally arranged between the plates 1408a, 1408b and the set of annular members 1412 surrounds the pieces of the wheel member. Figure 10C An example of the wheel member 1404 is shown arranged within the mold 1400. The wheel member 1404 can be substantially similar to any of the wheel members described herein and include a rim base portion 1220 and a main structural portion 1224, for which redundant explanations are omitted here for the sake of clarity. In some cases, the rim base portion 1220 and the main structure 1224 can be arranged within the mold 1400 and heat bonded to one another within the mold 1400. Additionally or alternatively, the wheel member 1404 can include a wheel segment 1406 that includes rim and main structural portions that are heat bonded to one another. In this regard, a plurality of circular segments can be arranged within the mold 1400 so as to define a continuous circular member that is formed internally and has a substantially seamless exterior.

[0182] Figure 10A Various examples of wheel components formed entirely of reinforced thermoplastic materials are depicted. Figure 10C Wheel components can be formed via a thermal bonding process. For example, one or more components of the rim base portion and the main structural portion, both formed of reinforced thermoplastic material, can be arranged relative to each other and joined together. The rim base portion and the main structural portion can be constructed in a variety of ways to facilitate thermal bonding. For example, the rim base portion and the main structural portion may include overlapping portions adapted to mechanically engage with each other to form an lap joint. Additionally or alternatively, the rim base portion and the main structural portion may be adapted to form edge joints and other structures. In some cases, one or both of the rim base portion or the main structural portion may be associated with other reinforced thermoplastic materials, such as reinforced thermoplastic materials suitable for defining reinforced areas of the wheel component, which are reinforced to receive spokes or other features of the bicycle. It should be understood that, although Figure 10C An example construction of the wheel component is shown, but other constructions are envisioned in other cases.

[0183] refer to Figure 12 and 15B The image shows wheel component 1500. Wheel component 1500 can be substantially similar to the various wheel components and reinforced thermoplastic structures described herein; redundant explanations thereof are omitted here for clarity. Wheel component 1500 in Figure 11 and 15B The image shows a first wall portion 1512a and a second wall portion 1512b. The first wall portion 1512a and the second wall portion 1512b cooperate to surround the wheel component 1500 and define a cavity 1506. Figure 13 and 15BIn the example of FIG. 15, the first wall portion 1512a and the second wall portion 1512b establish a rim base portion 1504 that defines an outer annular surface of the wheel component 1500 configured to engage a bicycle tire. The first wall portion 1512a and the second wall portion 1512b also establish a main structure portion 1510 that can be adapted to engage a bicycle spoke. The first wall portion 1512a and the second wall portion 1512b are mechanically joined at the rim base portion 1504 and the main structure portion 1510. For example, the first wall portion 1512a can include a joining feature 1520a and the second wall portion 1512b can include a joining feature 1520b. The joining features 1520a, 1520b can overlap one another at the rim base portion 1504, thereby forming a lap joint. Collectively, the overlap of the joining features 1520a, 1520b can define a reinforced region 1516b at the rim base portion. Further, the first wall portion 1512a can include a joining feature 1524a and the second wall portion 1512b can include a joining feature 1524b. The joining features 1524a, 1524b can overlap one another at the main structure portion 1510, thereby forming a lap joint. Collectively, the overlap of the joining features 1524a, 1524b can define a reinforced region 1516a at the main structure portion.

[0184] Referring to Figure 14 and 16B , a wheel component 1600 is shown. The wheel component 1600 can be substantially similar to the various wheel components and reinforced thermoplastic structures described herein; redundant explanations thereof are omitted here for the sake of clarity. The wheel component 1600 is shown in Figure 14 and 16B to include a first wall portion 1612a, a second wall portion 1612b, and a rim base portion 1604. The first wall portion 1612a, the second wall portion 1612b, and the rim base portion 1604 cooperate to include the wheel component 1600 and define a cavity 1606. In Figure 14 and 16BIn the example of FIG. 16, the rim base portion 1604 is a structural component that defines an outer annular surface of the wheel component 1600 configured to engage a bicycle tire. The first wall portion 1612a and the second wall portion 1612b establish a main structural portion 1610 that can be adapted to engage bicycle spokes. The first wall portion 1612a and the second wall portion 1612b mechanically engage at the main structural portion 1610. For example, the first wall portion 1612a can include an engagement feature 1624a and the second wall portion 1612b can include an engagement feature 1624b. The engagement features 1624aa, 1624b can overlap one another at the main structural portion 1610, thereby forming a lap joint. Collectively, the overlap of the engagement features 1624a, 1624b can define a reinforced region 1616 at the main structural portion 1610. Further, the first wall portion 1512a can include an engagement feature 1620a and the second wall portion 1612b can include an engagement feature 1620b. The engagement features 1620a, 1620b can be used to define edge joints with the main structural portion 1604. For example, the main structural portion 1604 can include an engagement feature 1605a that can mechanically engage with the engagement feature 1620a to define an edge joint. The main structural portion 1604 can also include an engagement feature 1605b that can mechanically engage with the engagement feature 1620b to define another edge joint.

[0185] Referring to Figure 14 and 17B , a wheel component 1700 is shown. The wheel component 1700 can be substantially similar to the various wheel components and reinforced thermoplastic structures described herein; redundant explanations thereof are omitted here for the sake of clarity. The wheel component 1700 is shown in Figure 15A-20B and 17B to include a rim base portion 1704 and a main structural portion 1712. The rim base portion 1704 and the main structural portion 1712 cooperate to enclose the wheel component 1700 and define a cavity 1706. In Figure 15A-20B and 17BIn the example of FIG. 17, the rim base portion 1704 is a structural component that defines an outer annular surface of the wheel component 1700 configured to engage a bicycle tire. The main structural portion 1710 can be adapted to engage spokes of a bicycle. The rim base portion 1704 is mechanically joined at the main structural portion 1710. For example, the rim base portion can include engagement features 1705a, 1705b. The main structural portion 1712 can include engagement features 1720a, 1720b. The engagement features 1720a, 1705a can define an edge joint between the main structural portion 1712 and the rim base portion 1704. Further, the engagement features 1720b, 1705b can define an edge joint between the main structural portion 1712 and the rim base portion 1704. FIG. 17 further illustrates the wheel component as including a reinforced region 1716 at the main structural portion 1712, for example, which can be adapted or reinforced to receive a series of spokes. For example, the wheel component 1700 can also include a reinforcement 1718, which can also be formed of a reinforced thermoplastic material. This reinforcement can overlap or be laminated with the main structural portion 1712 to define the reinforced region 1712.

[0186] Referring to Figure 15A-20B and 18B , a wheel component 1800 is shown. The wheel component 1800 can be substantially similar to the various wheel components and reinforced thermoplastic structures described herein; redundant explanations thereof are omitted here for the sake of clarity. The wheel component 1800 is shown in Figure 15A and 18B as including a first wall portion 1812a, a second wall portion 1812b, a first rim base portion 1804a, and a second rim base portion 1804b. The first wall portion 1812a, the second wall portion 1812b, the first rim base portion 1804a, and the second rim base portion 1804b cooperate to enclose the wheel component 1800 and define a cavity 1806. In Figure 15A and 18BIn the example of FIG. 18, first rim base portion 1804a and second rim base portion 1804b establish a rim base portion 1804 of wheel component 1800. Rim base portion 1804 defines an outer annular surface of wheel component 1800 that is configured to engage a bicycle tire. Further, first wall portion 1812a and second wall portion 1812b establish a main structure portion 1810 that can be adapted to engage bicycle spokes. First wall portion 1812a and second wall portion 1812b are mechanically joined at rim base portion 1804 and main structure portion 1810. For example, first wall portion 1812a can include engagement feature 1824a and second wall portion 1812b can include engagement feature 1824b. Engagement features 1824a, 1824b can overlap one another at main structure portion 1810, thereby forming a lap joint. Collectively, the overlap of engagement features 1824a, 1824b can define a reinforced region 1816a at rim base portion 1810. Further, first rim base portion 1804a and second rim base portion 1804b can also form a reinforced region 1816b at the rim base. For example, first rim base portion 1804a can include engagement feature 1818a and second rim base portion 1818b can include engagement feature 1818b. Engagement features 1818a, 1818b can overlap one another at rim base portion 1804, thereby forming a lap joint that defines reinforced region 1816b. Rim base portion 1804 is also adapted to form an edge joint with main structure portion 1810. For example, first wall portion 1812a can include engagement feature 1820a and first rim base portion 1804a can include engagement feature 1819a. Engagement features 1820a, 1819a can be arranged relative to one another to form an edge joint. Further, second wall portion 1812b can include engagement feature 1820b and second rim base portion 1804b can include engagement feature 1819b. Engagement features 1820b, 1819b can be arranged relative to one another to form an edge joint.

[0187] Referring to Figure 15A and 19B , a wheel component 1900 is shown. Wheel component 1900 can be substantially similar to the various wheel components and reinforced thermoplastic structures described herein; redundant explanations thereof are omitted here for the sake of clarity. Wheel component 1900 is shown in Figure 16A and 19B to include a first wall portion 1912a, a second wall portion 1912b, a rim base portion 1904, and an outer shell 1950. First wall portion 1912a, second wall portion 1912b, rim base portion 1904, and outer shell 1950 cooperate to enclose wheel component 1900 and define a cavity 1906. In Figure 16A and 19BIn the example, the rim base portion 1904 is a structural member defining the outer annular surface of a wheel component 1700 configured to engage a bicycle tire. Furthermore, a first wall portion 1912a, a second wall portion 1912b, and a housing 1950 form a main structural portion 1910 adapted to engage bicycle spokes. The first wall portion 1912a and the second wall portion 1912b are mechanically engaged at the main structural portion 1910. For example, the first wall portion 1912a may include an engagement feature 1924a, and the second wall portion 1912b may include an engagement feature 1924b. The engagement features 1924a and 1924b may overlap each other at the main structural portion 1910 to form an lap joint. In general, the overlap of the engagement features 1924a and 1924b may define a reinforcing region 1916a at the rim base portion 1910. Additionally, the rim base portion 1904 may also form a reinforcing region, for example... Figure 16A and 19B The reinforced regions 1916b and 1916c are shown. For example, the first wall portion 1912a may include a joining feature 1920a, which may be arranged relative to the rim base portion 1904 to define the reinforced region 1916b. Furthermore, the second wall portion 1912b may include a joining feature 1920b, which may be arranged relative to the rim base portion 1904 to define the reinforced region 1916b. The reinforced regions 1916a and 1916b may be reinforcing angles of the rim base portion 1904, which may be configured to support and / or enhance the function of certain bicycle tires engaged with the rim base portion 1904. The rim base portion 1904 is also adapted to form an edge joint with the main structural portion 1910. For example, the housing may include a joining feature 1952aa, and the rim base portion 1904 may include a joining feature 1905a. The joining features 1952a and 1905a may be arranged relative to each other to form an edge joint. Furthermore, the housing may include engagement feature 152bb and the rim base portion 1904 may include engagement feature 1905b. Engagement features 1902b and 1905b may be arranged relative to each other to form an edge joint.

[0188] refer to Figure 17A and 20B The image shows wheel component 2000. Wheel component 2000 can be substantially similar to the various wheel components and reinforced thermoplastic structures described herein; redundant explanations thereof are omitted here for clarity. Wheel component 2000 in Figure 17A and 20BThe first wall portion 2012a, the second wall portion 2012b, the first rim base portion 2004a, and the second rim base portion 2004b cooperate to enclose the wheel component 2000 and define a cavity 2006. In Figure 17A and 20B In the example of FIG. 20, the first rim base portion 2004a and the second rim base portion 2004b establish a rim base portion 2004 of the wheel component 2000. The rim base portion 2004 defines an outer annular surface of the wheel component 2000 that is configured to engage a bicycle tire. Further, the first wall portion 2012a and the second wall portion 2012b establish a main structure portion 2010 that can be adapted to engage bicycle spokes. The first wall portion 2012a and the second wall portion 2012b are mechanically joined at the rim base portion 2004 and the main structure portion 2010. For example, the first wall portion 2012a can include a joining feature 2024a and the second wall portion 2012b can include a joining feature 2024b. The joining features 2024a, 2024b can overlap one another at the main structure portion 2010, thereby forming a lap joint. Collectively, the overlap of the joining features 2024a, 2024b can define a reinforced region 2016a at the rim base portion 2010. Additionally, the first rim base portion 2004a and the second rim base portion 2004b can also form a reinforced region 2016b at the rim base. The rim base portion 2004 is further adapted to form a fillet joint with the main structure portion 2010. For example, the first wall portion 2012a can include a joining feature 2020a and the first rim base portion 2004a can include a joining feature 2019a. The joining features 2020a, 2019a can be arranged relative to one another to form a fillet joint. Additionally, the second wall portion 2012b can include a joining feature 2020b and the second rim base portion 2004b can include a joining feature 2019b. The joining features 2020b, 2019b can be arranged relative to one another to form a fillet joint.

[0189] Figure 18A Further examples of thermal bonding of reinforced thermoplastic components are depicted. In particular, Figure 18A A multi-stage thermal bonding technique is depicted. For example, in some cases, it can be desirable to complete spoke base bonding or welding (e.g., bonding components of the main structure portion to one another) and then complete channel bonding or welding (e.g., bonding components of the rim base portion to one another and / or to the main structure portion). Thus, it should be appreciated that the following techniques can be adapted for thermally bonding any reinforced thermoplastic materials to one another, including thermally bonding to form circular segments and / or continuous circular components.

[0190] Referring toFigure 18A and 21B depict a first example of a multi-stage thermal bonding technique. Figure 19A Operation 2100a is shown to perform spoke base welding or bonding, and Figure 19A Operation 2100b is shown to perform channel welding or bonding. As Figure 19A shown, the main structure portion 2150 can generally be held within a mold. The mold can include a first half 2104a and a second half 2104b. The first and second halves 2104a, 2104b can operate as external support members that clamp the pieces of the wheel component in the mold. First and second bracket portions 2114a, 2114b can contact and engage the main structure portion 2150 within the mold. An annular member 2106 can hold the main structure portion 2150 therein, thereby helping to hold the portion 2150 against the brackets 2114a, 2114b. A cavity 2152 can be defined by the main structure portion 2150 and the annular member 2106. Figure 19A Electrically conductive rings 2108a, 2108b are also shown. The electrically conductive rings 2108a, 2108b can be used to generate heat within the bracket portions 2114a, 2114b, which can be used to thermally bond the pieces of the main structure portion 2150 and / or otherwise facilitate spoke base welding of the wheel component. Phenolic insulating rings 2112a, 2112b can provide electrical insulation features that limit the flow of heat to non-target areas during thermal bonding. Reference is made to Figure 20A Operation 2100b is shown to thermally bond the rim base portion 2156 to the main structure portion 2150. In operation 2100b, heat is generated near the channels of the rim base portion 2156 via the electrically conductive rings 2132a, 2132b. Phenolic insulating rings 2128a, 2128b are provided to limit the flow of heat to non-target areas during thermal bonding.

[0191] Reference is made to Figure 20A and 22B depict a second example of a multi-stage thermal bonding technique. Figure 20A Operation 2200a is shown to perform spoke base welding or bonding, and Figure 21A-25B Operation 2200b is shown to perform channel welding or bonding. As Figure 21A-25BAs shown, the main structure portion 2250 can generally be held within a mold. The mold can include a first half 2204a and a second half 2204b. The first and second halves 2204a, 2204b can operate as external support members that hold the pieces of the wheel component in the mold. First and second bracket portions 2214a, 2214b can contact and engage the main structure portion 2250 within the mold. An annular member 2206 can hold the main structure portion 2250 therein, thereby helping to hold the portion 2250 against the brackets 2214a, 2214b. The annular member 2206 can also extend toward and press against the main structure portion 2250 to help define the profile 2253 during thermal bonding. Figure 21A Electrically conductive rings 2208a, 2208b are also shown. The electrically conductive rings 2208a, 2208b can be used to generate heat within the bracket portions 2214a, 2214b, which can be used to thermally bond the components of the main structure portion 2250 and / or otherwise facilitate spoke base welding of the wheel component. Phenolic insulating rings 2212a, 2212b can provide electrical insulation features that limit the flow of heat to non-target areas during thermal bonding. Reference is made to Figure 21A , operation 2200b illustrates thermal bonding of the rim base portion 2256 with the main structure portion 2250. A cavity 2252 can be defined by the main structure portion 2250 and the rim base portion 2256. In operation 2200b, heat is generated via the electrically conductive rings 2232a, 2232b near the channels of the rim base portion 2256. Phenolic insulating rings 2228a, 2228b are provided to limit the flow of heat to non-target areas during thermal bonding.

[0192] Reference is made to Figure 21B and 23B , a third example of a multi-stage thermal bonding technique is depicted. Figure 21A Operation 2300a is shown that performs spoke base welding or bonding, and Figure 21A Operation 2300b is shown that performs channel welding or bonding. As Figure 21B shown, the main structure portion 2350 can generally be held within a mold. The mold can include a first bracket portion 2314a, a second bracket portion 2314b, a third bracket portion 2314c, and a fourth bracket portion 2014d, each of which cooperate to contact and engage the main structure portion 2350 within the mold. A cavity 2352 can be defined by the main structure portion 2350 and the third and fourth brackets 2314c, 2314d. Figure 22AConductive rings 2308a, 2308b are also shown. Conductive rings 2308a, 2308b can be used to generate heat within the cradle portions 2314a, 2314b, which can be used to thermally bond components of the main structure portion 2350 and / or otherwise facilitate spoke base welding of the wheel components. Phenolic insulating rings 2312a, 2312b can provide electrical insulation features that limit heat flow to non-target areas during thermal bonding. Referring to Figure 22B Operation 2300b illustrates thermal bonding of the rim base portion 2356 with the main structure portion 2350. In operation 2300b, heat is generated via conductive rings 2332a, 2332b near the channels of the rim base portion 2356. Phenolic insulating rings 2328a, 2328b are provided to limit heat flow to non-target areas during thermal bonding.

[0193] Referring to Figure 22A and 24B a fourth example of a multi-stage thermal bonding technique is depicted. Figure 23A Operation 2400a illustrates performing spoke base welding or bonding, and Figure 23B Operation 2400b illustrates performing channel welding or bonding. As Figure 23A illustrated, the main structure portion 2450 can generally remain within a mold. The mold can include a first cradle portion 2414a and a second cradle portion 2414b, each of which cooperate to contact and engage the main structure portion 2450 within the mold. A cavity 2452 can be defined by the main structure portion 2450 and the cradles 2414a, 2414b. Figure 24A Conductive rings 2408a, 2408b are also shown. Conductive rings 2408a, 2408b can be used to generate heat within the cradle portions 2414a, 2414b, which can be used to thermally bond components of the main structure portion 2450 and / or otherwise facilitate spoke base welding of the wheel components. Phenolic insulating rings 2412a, 2412b can provide electrical insulation features that limit heat flow to non-target areas during thermal bonding. Referring to Figure 24B Operation 2400b illustrates thermal bonding of the rim base portion 2456 with the main structure portion 2450. In operation 2400b, heat is generated via conductive rings 2432a, 2432b near the channels of the rim base portion 2456. Phenolic insulating rings 2428a, 2428b are provided to limit heat flow to non-target areas during thermal bonding.

[0194] Referring to Figure 24A and 25B a fifth example of a multi-stage thermal bonding technique is depicted. Figure 25A Operation 2500a illustrates performing spoke base welding or bonding, and Figure 25B Operation 2500b illustrates performing channel welding or bonding. AsFigure 25A As shown, the main structure portion 2550 can generally be held within a mold. The mold can include a first half 2504a and a second half 2504b. The first and second halves 2504a, 2504b can operate as external support members that hold the pieces of the wheel component in the mold. The first and second brace portions 2514a, 2514b can contact and engage the main structure portion 2550 within the mold. The annular member 2506 can hold the main structure portion 2550 therein, thereby helping to hold the portion 2550 against the braces 2514a, 2514b. The cavity 2552 can be defined by the main structure portion 2550 and the annular member 2506. Figure 25A Also shown are conductive rings 2508a, 2508b. The conductive rings 2508a, 2508b can be used to generate heat within the brace portions 2514a, 2514b, which can be used to thermally bond the pieces of the main structure portion 2550 and / or otherwise facilitate spoke base welding of the wheel component. Phenolic insulating rings 2512a, 2512b can provide electrical insulation features that limit the flow of heat to non-target areas during thermal bonding. Reference is made to Figure 25B Operation 2500b illustrates thermal bonding of the rim base portion 2556 to the main structure portion 2550. In operation 2500b, heat is generated near the channels of the rim base portion 2556 via the conductive rings 2532a, 2532b. Phenolic insulating rings 2528a, 2528b are provided to limit the flow of heat to non-target areas during thermal bonding. Figure 25B Another annular member 2507 is also shown, which is used to hold the rim base portion 2556 near the main structure portion 2550. The other annular member 2507 can be adapted to define a contoured surface that matches and / or is used to form a matching contour of the rim base portion 2556, such as a contoured surface used to engage a bicycle tire.

[0195] Turning to Figure 26 A wheel assembly 2600 is shown. The systems and techniques of the present disclosure can be used to produce a variety of shapes and components from reinforced thermoplastic materials. This can include shapes and components having curved contours and / or substantially hollow interiors, such as the various wheel components and assemblies described herein. The systems and techniques can also be used to produce other wheel designs, such as the wheel component 2600, which can substantially define a three-spoke shape.

[0196] For example, the wheel component 2600 can have a rim 2604 having a substantially circular profile defining an outer periphery of the wheel component 2600. According to various methods described herein, the rim 2604 can be smooth and substantially seamless. The wheel component can also include a series of spokes 2608. The spokes 2608 can be integrally formed with the rim 2604 and associated therewith at one or more curved regions 2620. While the series of spokes 2608 includes five spokes in Figure 26 the example, it should be appreciated that the series of spokes 2608 more generally cooperate to define a three-spoke design of the wheel component 2600. In this regard, the series of spokes 2608 can include three spokes integrally formed with the rim 2604. The wheel component 2600 can also include a hub 2624. The hub 2624 can be integrally formed with some or all of the series of spokes 2608 and associated therewith at one or more curved regions 2624. The hub can define an opening 2616 adapted to receive a component of a bicycle.

[0197] The wheel component 2600 can be formed entirely from a reinforced thermoplastic material. In this regard, each of the rim 2604, the series of spokes 2608, and the hub 2612 can be formed from a reinforced thermoplastic material. The rim 2604, the series of spokes 2608, and the hub 2612 can be bonded to one another via any of the thermal bonding processes described herein. In some cases, one or more of the rim 2604, the series of spokes 2608, and the hub 2612 can be formed as a substantially hollow component.

[0198] Systems and techniques for forming components from reinforced thermoplastic materials are contemplated and described herein, which can be used to construct a variety of applications requiring a sufficiently high strength-to-weight ratio. For example, the systems and techniques described herein can be applicable to the production of components having sealed, hollow interiors and / or defining complex, seamless exterior profiles. As one illustration, Figure 27A-27B applications of the systems and techniques described herein to wind turbines and wind turbine blades are depicted. However, it should be appreciated that, Figure 27A-27B the examples are intended to illustrate other non-wheel applications of the systems and techniques described herein, and are not limiting.

[0199] Referring to Figure 27A , a wind turbine 2700 is shown. The wind turbine 2700 can include a blade 2704 associated with a rotatable structure 2708. The wind turbine 2700 can also include a device 2712 connected to the rotatable structure 2708 and configured to transfer energy as the rotatable structure 2708 rotates. The blade 2704 can be sufficiently strong to withstand wind forces and gravitational forces, but lightweight for rotation. According to one or more techniques described herein, the blade 2704 can be formed entirely from a reinforced thermoplastic material.

[0200] For example, reference is made to Figure 27B , which depicts a cross-sectional view of a vane 2704 taken along line 27B-27B of Figure 27A . In accordance with the technology described herein, the vane 2704 can have a substantially smooth and seamless outer profile 2750. The vane 2704 can also include a cavity 2752. The cavity 2752 can be substantially sealed from the outer environment. The vane 2704 can be formed to meet target aerodynamic specifications, and thus define a leading edge 2756 and a trailing edge 2758. One or both of the leading edge 2756 or the trailing edge 2758 can be curved or partially curved. Further, one or both of the leading edge 2756 or the trailing edge 2758 can define a sharp edge of the vane 2704. The reinforced thermoplastic material can be tailored to have a thickness 2754.

[0201] To facilitate the reader's understanding of the various functionality of the examples discussed herein, reference is now made to the flowcharts of Figure 28 , 29 , 30, and 31, which illustrate processes 2800, 2900, 3000, and 3100, respectively. Although specific steps (and sequences of steps) of the methods presented herein have been described and will be discussed, other methods consistent with the teachings presented herein that include more, fewer, or different steps (and sequences of steps) are contemplated and included within the scope of the disclosure.

[0202] In this regard, reference is made to Figure 28 , the process 2800 generally relates to a method of manufacturing a fully reinforced thermoplastic wheel component. The process 2800 can be used with any of the wheel components and molds described herein, such as, for example, the wheel components 300, 400, 500, 600, 800, 1000; and the molds 900, 1050, 1200; and variations and combinations thereof.

[0203] At operation 2804, a rim base portion and a main structure portion can be arranged within a mold compartment. The rim base portion and the main structure portion can be formed of a reinforced thermoplastic material. For example and with reference to Figure 10A and 10B , the rim base portion 1004 and the main structure portion 1010 can be arranged in the mold compartment 1040. The rim base portion 1004 and the main structure portion 1010 can be formed of a reinforced thermoplastic material, such as any of the reinforced thermoplastic materials described herein, for which redundant explanations are omitted here for the sake of clarity.

[0204] At operation 2808, a region of the compartment between the rim base portion and the main structure portion can be pressurized. For example and with reference to Figure 10CThe mold compartment 1060 can be pressurized. The inflation member 1070 can deliver pressurized air to an area of the mold 1050 substantially between the rim base portion 1084 and the main structure portion 1080 to maintain the shape of the cavity of the wheel component during thermal bonding.

[0205] At operation 2812, the rim base portion and the main structure portion can be bonded by heating the reinforced thermoplastic material above a melting temperature. For example and with reference to Figure 11 The rim base portion 1084, as well as the first and second wall portions 1082a, 1082b, can be thermally bonded to one another. For example, the mold 1050 can be subjected to heat, such as heat in excess of 450 degrees, which causes one or more of the main structure portion 1084, the first wall portion 1082a, and / or the second wall portion 1082b to transition to or transition into a partially molten or molten state.

[0206] At operation 2816, a cavity can be defined by the rim base and main structure portions, and the cavity can be sealed. For example and with reference to Figure 11 The cavity of the wheel component 1050 can be sealed. The inflation member 1170 can be removed from the cavity after thermal bonding of the parts of the wheel component 1110. In some cases, the opening 1085 can be allowed to close as the inflation member 1170 is withdrawn. For example, the reinforced thermoplastic material of the rim base portion 1004 can be largely self-sealing. Additionally or alternatively, a higher temperature film, plug, or other structure can cooperate to seal the opening 1085.

[0207] In this regard, reference is made to Figure 29 The process 2900 generally involves a method of manufacturing a fully reinforced thermoplastic wheel component. The process 2900 can be used with any of the wheel components and molds described herein, such as the wheel components 300, 400, 500, 600, 800, 1000; and the molds 900, 1050, 1200; and variations and combinations thereof.

[0208] At operation 2904, a rim base portion can be formed from a first reinforced thermoplastic material. For example and with reference to Figure 7A The rim base portion 708 can be formed from a first thermoplastic material. A stamping operation can manipulate the first thermoplastic material into the shape of the rim base portion 708.

[0209] At operation 2908, a main structure portion can be formed from a second reinforced thermoplastic material. For example and with reference to FIGS. 7B and 7C, the wall portions 718, 728 can be formed from a second thermoplastic material. A stamping operation can manipulate the second thermoplastic material into the shape of the wall portions 718, 728.

[0210] At operation 2912, the fully reinforced thermoplastic wheel component can be formed as a continuous circular component. The operation of forming can be performed by thermally bonding the rim base portion and the main structure portion to one another within a mold compartment. For example and with reference to Figure 14 , the rim base portion 1220 and the main structure portion 1224 can be mechanically joined to one another. The rim base portion 1220 and the main structure portion 1224 can be mechanically joined to one another and disposed within a mold 1200, which can define a continuous circular shape therein. The mold 1200 can be subjected to heat, allowing the rim base portion 1220 and the main structure portion 1224 to thermally bond to one another therein. The rim base portion 1220 and the main structure portion 1224 can be removed from the mold 1200 as an integrally formed structure having a continuous, substantially seamless outer profile.

[0211] In this regard, reference is made to Figure 30 , the process 3000 generally involves a method of manufacturing a fully reinforced thermoplastic wheel component. The process 3000 can be used with any of the wheel components and molds described herein, such as the wheel components 300, 400, 500, 600, 800, 1000; and the molds 900, 1050, 1200; and variations and combinations thereof.

[0212] At operation 3004, a film can be laid up onto the reinforced thermoplastic material. The film can have a higher melting temperature than the reinforced thermoplastic material. For example and with reference to Figure 7D , the film 754 can be laid up to the mold shape 762. The film 754 can have a higher melting temperature than the mold shape 762, which is formed from the reinforced thermoplastic material. Further, as shown in Figure 7E , the film 784 can be laid up to the reinforcement panel 792. The film 784 can have a higher melting temperature than the reinforcement panel 792.

[0213] At operation 3008, a cavity can be defined with the reinforced thermoplastic material and the laid up film. For example and with reference to FIGS. 8 and 9, the cavity 801 can be defined using the collection of the rim base portion 804 and the main structure portion 810, all of which can be formed from the reinforced thermoplastic material having the laid up film of higher melting temperature.

[0214] At operation 3012, the cavity can be sealed using the film. For example and with reference to Figure 11 , the rim base portion 1004 can include the film of higher melting temperature described herein. In this regard, the reinforced thermoplastic material and the film of the rim base 1004 cool according to different thermal characteristics. The different thermal characteristics can allow the rim base portion 1004 to be substantially self-sealing, thereby closing the aperture 1005 upon cooling.

[0215] In this regard, reference is made to Figure 31, process 3100 generally involves a method of manufacturing a fully reinforced thermoplastic wheel component. Process 3000 can be used with any of the wheel components and molds described herein, such as wheel components 300, 400, 500, 600, 800, 1000; and molds 900, 1050, 1200; and variations and combinations thereof.

[0216] At operation 3104, the rim base portion and the main structure portion can be arranged to define a cavity of the fully reinforced thermoplastic wheel component. For example and with reference to Figure 12 and 13 , the rim base portion 1204 and the walls 1208a, 1208b can be arranged to define a cavity 1210. The rim base portion 1204 and the walls 1208a, 1208b can be arranged to define the cavity 1210 within a mold that is adapted to form a thermal bond between the parts held therein.

[0217] At operation 3108, the cavity can be pressurized by at least partially inserting an inflation component into the cavity. The inflation component can be at least partially formed of a material having a melting temperature that is higher than a melting temperature of a material used to form the rim base portion and the main structure portion. For example and with reference to Figure 12 and Figure 13 , the cavity 1210 can be pressurized by at least partially inserting the inflation component 1250 into the cavity 1210. In particular, the tip 1258 can be inserted through the opening 1206 and used to direct pressurized air into the cavity 1210 in order to maintain the shape of the cavity 1210 during the thermal bonding process. The tip 1258 can be at least partially formed of a material having a melting temperature that is higher than a melting temperature of the rim base portion 1204.

[0218] At operation 3112, the cavity can be sealed using the inflation component. For example and with reference to Figure 12 and 13 , the tip 1258 can be separated from the remainder of the inflation component 1250, such as separating the tip 1258 from the shaft portion 1254. The tip 1258 can remain at least partially engaged within the hole 1206, defining a plug or partial plug for air to flow therethrough. Further, the tip 1262 can cool according to different thermal properties than the reinforced thermoplastic material of the rim base portion 1204. The different thermal properties can allow the rim base portion 1204 to substantially self-seal, thereby closing the hole 1005 as the tip 1262 cools.

[0219] With reference to Figure 32The process 3200 generally involves a method of manufacturing a wall portion of a fully reinforced thermoplastic wheel component. The process 3200 can be used with any of the wheel components and molds described herein, such as the wheel components 300, 400, 500, 600, 800, 1000; and the molds 900, 1050, 1200; and variations and combinations thereof.

[0220] At operation 3204, a first ply of reinforced thermoplastic material is provided. For example and with reference to Figure 8A The first ply 810 is provided. The first ply 810 can include or be formed of a reinforced thermoplastic material, such as any of the materials described herein. The first ply 810 can have a first edge 812. The first ply 810 can be disposed relative to the wall portion profile 804. For example, the first ply 810 can be disposed relative to the wall portion profile 804 to define an angle θι with a central axis of the circular profile defined by the center 806.

[0221] At operation 3208, a second ply of reinforced thermoplastic material is provided. For example and with reference to Figure 8B The second ply 820 is provided. The second ply 820 can include or be formed of a reinforced thermoplastic material, such as any of the materials described herein. The second ply 820 can have a second edge 822. The second ply 820 can be disposed relative to the wall portion profile 804. For example, the second ply 820 can be disposed relative to the wall portion profile 804 to define an angle θ2with a central axis of the circular profile defined by the center 806.

[0222] At operation 3212, the first ply and the second ply are overlapped within one another so as to define an arrangement of plies. For example and with reference to Figure 8A and 8B The first ply 810 and the second ply 820 are overlapped with one another to define the arrangement of plies of the radial pattern 802. In one example, the first and second plies are overlapped with one another such that the first edge 812 and the second edge 822 are substantially transverse to one another. However, it should be appreciated that the orientation of the first and second edges 812, 822 can be specifically selected and / or designed to have any appropriate orientation to facilitate the wall strength of the wheel component.

[0223] At operation 3216, the arrangement of plies is provided to define a radial pattern of the wheel component of the wall portion. For example and with reference to Figure 8A and 8B A plurality of groupings or arrangements of the plies 810, 820 can be provided and radially arranged along the profile 804. The radial arrangement of the plies 810, 802 can define the radial cross pattern 802, such as described with reference to Figure 8AThe illustrated radial cross pattern. The stack 800 including the cross-ply pattern 802 can be subsequently shaped to form the wall portion 850 according to any of the forming techniques described herein.

[0224] Other examples and implementations are within the scope and spirit of the disclosure and appended claims. For example, features implemented in hardware can also be implemented as software functions, and vice versa. Further, as used in this document, "or" as used in the context of alternatives, such as "A or B," means that at least one of A or B is true. Also, as used in this document, the conjunction "and" as used in the context of alternatives, such as "A and B," means that at least one of A or B is true. Furthermore, the term "exemplary" does not mean that an example is preferred or better than other examples.

[0225] The foregoing description, for purposes of explanation, used specific nomenclature to provide a thorough understanding of the described examples. However, it will be apparent to one skilled in the art that the specific details are not required in order to practice the described examples. Thus, the foregoing descriptions of specific examples are presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the examples to the precise forms disclosed. Many modifications and variations are possible in view of the above teachings.

Claims

1. A wheel component comprising: a rim base portion at least partially defining a cavity and an outer annular surface configured to engage a bicycle tire; and a main structure portion at least partially defining the cavity; wherein: the rim base portion comprises a reinforced thermoplastic material; the main structure portion comprises a reinforced thermoplastic material; the rim base portion is bonded to the main structure portion to form a unitary structure; the main structure portion comprises a first wall portion and a second wall portion; the first wall portion overlaps the second wall portion in a direction parallel to a longitudinal axis of the main structure portion; and the first wall portion is thermally bonded to the second wall portion along an overlap between the first wall portion and the second wall portion to form a seamless interface between the first wall portion and the second wall portion.

2. The wheel component of claim 1, wherein: the first wall portion and the second wall portion of the main structure portion are formed from a reinforced thermoplastic material; the reinforced thermoplastic material of the first wall portion and the second wall portion comprises a plurality of overlapping plies defining radially intersecting plies; the plurality of overlapping plies comprises a first ply having a first edge and a second ply having a second edge; the first edge and the second edge define an offset angle between 22.5 and 75 degrees with respect to a radius extending from the outer annular surface to a central axis of a continuous circle defined by the outer annular surface.

3. The wheel component of claim 1, wherein: the first wall portion and the second wall portion of the main structure portion are formed from a reinforced thermoplastic material; the reinforced thermoplastic material of the first wall portion and the second wall portion comprises a plurality of overlapping plies defining radially intersecting plies; the plurality of overlapping plies comprises a first ply and a second ply; the first ply and the second ply define an arrangement of plies; the wheel component further comprises a plurality of arrangements of plies disposed in a radial pattern; and the plurality of arrangements of plies define the first wall portion and the second wall portion.

4. The wheel component of claim 1, wherein, the rim base portion and the main structure portion are at least one of thermally bonded, chemically bonded, or adhesively bonded.

5. The wheel component of claim 1, wherein: the main structure portion defines an inner annular surface configured to receive a series of spokes; and the main structure portion is configured to withstand a pull force of at least 300 pounds of a spoke of the series of spokes.

6. The wheel component of claim 5, wherein, the main structure portion defines a reinforcement layer along the inner annular surface.

7. The wheel component of claim 1, wherein: the reinforced thermoplastic material comprises: a thermoplastic material; and fibers disposed within the thermoplastic material; and the fibers comprise at least one of carbon fibers, glass fibers, Kevlar fibers, or basalt fibers.

8. The wheel component of claim 7, wherein, the fibers define at least 30% of a volume of the reinforced thermoplastic material.

9. A wheel component comprising a continuous reinforced thermoplastic material defining: a rim base portion having a first outer surface; a main structural portion connected to the rim base portion and having a second outer surface, the main structural portion defining a sidewall portion of the wheel component; and a circular cavity; wherein the main structural portion includes: a first wall portion; a second wall portion; and a thermal bond extending along an overlap between the first wall portion and the second wall portion in a direction parallel to a longitudinal axis of the main structural portion, the thermal bond forming a seamless interface between the first wall portion and the second wall portion.

10. The wheel component of claim 9, wherein: neither the first outer surface nor the second outer surface has a mark associated with ejection of a bladder from the cavity; and the mark includes a through portion of the wheel component extending between the circular cavity and an external environment, a transverse dimension of the through portion being greater than 15 millimeters (mm).

11. The wheel component of claim 10, wherein, the first outer surface cooperates with the second outer surface to seal the circular cavity from an external environment.

12. The wheel component of claim 9, wherein: the circular cavity is formed by maintaining a pressurized region between the rim base portion and the main structural portion during a thermal bonding process.

13. The wheel component of claim 9, wherein, the circular cavity includes a self-sealing membrane.

14. The wheel component of claim 9, wherein, the continuous reinforced thermoplastic material exhibits a bending strength of at least 740 MPa.

15. A method of manufacturing a reinforced thermoplastic wheel component, the method comprising: forming a rim base portion from a reinforced thermoplastic material; forming a main structural portion from a reinforced thermoplastic material; thermally bonding the rim base portion to the main structural portion within a mold compartment to form a continuous circular component; and sealing an opening in the rim base portion with the reinforced thermoplastic material of the rim base portion to seal a cavity defined by the main structural portion and the rim base portion.

16. The method of claim 15, wherein, forming the main structural portion includes arranging a first ply of reinforced thermoplastic material relative to a second ply of reinforced thermoplastic material to form radially crossing plies.

17. The method of claim 16, wherein, at least one of the first ply or the second ply defines a bias angle between 22.5 and 75 degrees relative to a radius extending from an outer annular surface to a central axis of the wheel component.

18. The method of claim 15, wherein, forming the main structural portion includes stamping the reinforced thermoplastic material to define an inner annular surface configured to be associated with a series of spokes.

19. The method of claim 15, wherein, forming the reinforced thermoplastic wheel component includes heating the reinforced thermoplastic material of the rim base portion and the reinforced thermoplastic material of the main structural portion above a common melting temperature.

20. The method of claim 19, wherein, forming the reinforced thermoplastic wheel component includes pressurizing a region of the mold compartment generally between the rim base portion and the main structural portion to define the cavity.

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