Spoke star made of fiber-plastic composite

Abstract

This invention relates to a spoke star made of a fiber-plastic composite, the spoke star being constructed as a star-shaped closed loop, wherein the spoke star has spokes between an inner periphery on the hub side and an outer periphery on the rim side of the spoke star, and in the spoke star, a single fiber bundle extends multiple times along the spokes of the spoke star between the inner and outer peripheries. Within the scope of this invention, the spokes are constructed as double spokes, wherein the spokes have a collar on the outer periphery on the rim side of the spoke star. The collar enables better load transfer to the spoke star.

Description

Technical Field

[0001] The present invention relates to a spoke star made of a fiber-plastic composite, the spoke star being constructed as a star-shaped closed loop, wherein the spoke star has spokes between the inner periphery on the hub side and the outer periphery on the rim side of the spoke star, and in the spoke star, a single fiber bundle extends multiple times along the spokes of the spoke star between the inner and outer peripheries. Background Technology

[0002] A spoked star is a structure that is at least approximately star-shaped, with its radiating elements consisting of spokes. A spoked star has at least two spokes.

[0003] Spoke wheels made of fiber composite materials are known.

[0004] In the prior art, motor vehicle wheel rims made of fiber-plastic composite materials are known, which mimic cast wheel rims. They are shaped by fiber pads mounted onto a molding die. The impregnated fiber pads are then cured to manufacture spoked wheels.

[0005] The drawback of this prior art is that it requires pre-formed molding elements to give the rim its shape. Such molding is relatively labor-intensive to manufacture and correspondingly expensive. Furthermore, they can only produce specific types of spoked wheels with specific dimensions. Additionally, fiber utilization is not optimal among known solutions.

[0006] DE102018113797A1 describes a method for manufacturing a spoke star-shaped component having one or more continuous fiber bundles using a manufacturing apparatus. The manufacturing apparatus has a plurality of deflection devices on the rim ring side and a plurality of deflection devices on the hub side. To form the rim star-shaped component, continuous fiber bundles are wound into fiber rolls around at least a portion of the deflection devices on the rim ring side, and a portion of the deflection devices on the rim ring side is moved toward the interior of the arrangement.

[0007] DE9416688U1 describes a hub for securing a joint in a workwheel with spokes that are inserted in reverse. Here, the head of the unbent spoke is secured in the rim, and the spoke is tensioned via a joint located in the hub or other means located on the hub. The rim-side end of the spoke, made of a fiber composite material, can be fitted into a slot parallel to the plane of the workwheel, and the rim-side end forms a closed or open eyelet toward the axis of the workwheel. A retaining pin is provided in the eyelet to prevent the spoke from being pulled out due to tension.

[0008] DE102007026782A1 relates to a rim made of a fiber composite material. Structural elements, such as spoke ends or individual spoke ends, may be guided around the rim in a loop, including, for example, roving sections, stitching portions embedded in the loop, or / or pre-reinforced structural elements.

[0009] DE102008007722A1 describes a wheel spoke with a tension spoke. The spoke is made of a composite material and includes a tapered tension body having a middle section and two ends. The body extends on one side of each end by a fixing section, wherein the body and the fixing section are connected by a transition region. The spoke has at least one section on its surface having a cross-section reinforced relative to the cross-section of the middle section, wherein the section with the reinforced cross-section at least covers the transition region between the tension body and the mounting fixing section. The fixing element can be applied as a sandwich between the two layers of the rim and thus abuts against the inner wall of the rim.

[0010] DE102008046255B3 describes a spoke made of carbon fiber for a bicycle wheel, the spoke having an eyelet constructed at at least one end, wherein the eyelet is divided by carbon fiber into two mutually separated opening regions. A core element made of a material substantially incompressible with respect to the force acting when the spoke is tensioned is inserted into each of the two opening regions. Another eyelet with only one opening region may be provided at the other end of the spoke. This opening region is semi-circular on one side and gradually tapers on the other side. A clamping block with a fitting element engages in this eyelet and secures the eyelet to the hub.

[0011] DE102017116754A1 describes a system work wheel with spokes based on a high-efficiency fiber material. Here, the spokes can be tensioned by means of at least one tensioning element, and the cross-section of the spokes is approximately square in the untensioned state and substantially circular in the tensioned state.

[0012] DE102017219061B4 relates to a vehicle wheel comprising a rim for housing a tire and a hub having spokes connecting the rim. The spokes are composed of spoke segments made of injection-molded thermoplastic material, and at least one spoke reinforcing element is at least partially embedded in the spoke segment, the spoke reinforcing element being at least partially made of fiber-reinforced plastic. A collar of the reinforcing element projecting from the spoke on the rim side is guided radially outward around at least one segment of the rim reinforcing element.

[0013] EP0089809A1 describes a method for manufacturing fiber-reinforced objects from a fibrous material incorporated in a curable matrix material via resin injection molding. These objects comprise two or more spokes extending from a hub section. Each spoke has a loop shape. The fibrous material is arranged such that at least as many rovings as spokes are arranged around each spoke in a continuous path along the hub section. Each roving overlaps with each other roving at least a portion of its length.

[0014] DE29824507U1 relates to a composite spoke core for a spoked wheel, the composite spoke core bearing tensile loads. The composite spoke core comprises a continuous winding of multi-turn fibers based on at least two parallel straight segments, said segments being joined at their ends by two circular segments. The straight segments can here be combined into a single bundle. Here, the core may have a fastener at each end for connection to a rim and hub. This fastener is constituted by a bolt or bolt segment, acting on the inside of the continuous winding of the core.

[0015] EP1800897B1 describes a wheel including a rim, a hub, and at least one connecting device between the rim and the hub. The connecting device includes compound spokes and a first connecting mechanism between the spokes and the rim or hub, wherein the spokes include an elongated body extending longitudinally between a first end and a second end. The body and the ends include fibers, wherein the fibers are arranged to form a first loop at the first end. The first connecting mechanism includes a first insert disposed in the first loop, a first rod fixed to the first insert, wherein the first rod is oriented longitudinally, and a first threaded connection member or fixing member is defined on the first rod.

[0016] US2008 / 0315675A1 relates to a wheel comprising a rim, a hub, and at least one spoke connecting the rim and the hub. The spokes are made of a composite material, wherein each spoke has a connecting element for detachably connecting the spoke to the hub. The connecting element is at least partially machined into the spoke by being formed together with it. The connecting element may be a pin with a shoulder. The spoke may be a double-spoke design.

[0017] WO1991 / 013771A2 describes a non-rigid spoke comprising an intermediate member extending between a first end and a second end, a first fixing mechanism fixed at the first end of the spoke, and a second fixing mechanism disposed at the other end of the spoke. One of the fixing mechanisms mentioned herein may include a hook.

[0018] WO2010 / 057857A1 relates to a wheel, particularly for bicycles or motorcycles, having a rim having a polygonal, preferably V-shaped, cross-section. The rim has arcuate inserts or guides in its inner region for supporting and sliding complementary shaped ends of spokes, which are shaped like open collars. The ends of the spokes can be inserted into correspondingly provided openings arranged in the rim in the region adjacent to the arcuate guides or inserts. Summary of the Invention

[0019] The objective of this invention is to optimize spoke star-shaped components made of fiber-plastic composites.

[0020] The task is solved by a spoke star made of a fiber-plastic composite, the spoke star being constructed as a star-shaped closed loop having at least two spokes between the inner periphery on the hub side and the outer periphery on the rim side of the spoke star, in which a single fiber bundle extends multiple times along the spokes of the spoke star between the inner and outer peripheries. The spokes are constructed as double spokes, wherein the two spokes of the double spokes are connected by a plastic matrix, and the spoke arrangement structure inside the spoke star imitates the spoke arrangement structure of a traditional wheel with steel spokes. The spoke star is continuously made into a closed loop made of fiber composite material. The spokes have a collar on the outer periphery of the spoke star on the rim side, and a collar on the inner periphery of the spoke star on the hub side. The collar on the inner periphery of the spoke star on the hub side enables the spoke star to be fixed to bolts arranged on the hub. The fibers extend substantially parallel and in opposite directions in the two spokes of the double spokes.

[0021] A fiber bundle is preferably a bundle composed of multiple continuous fibers, such as, in particular, a single or multiple rovings with unidirectional fiber orientation, or a belt, bundled prepreg, elongated prepreg, or elongated loose-knitted fabric or woven fabric. Continuous fibers (as is commonly used in the language of fiber composite technology) are not actually infinitely long. In this patent application, continuous fibers are defined as fibers with special properties that are longer than the spokes. However, it is also conceivable to connect fibers shorter than the spokes into longer fiber bundles and use them.

[0022] For example, a spoke star can be incorporated as part of a spoked wheel. It can be used to connect a hub to a rim. Preferably, the spoke star has an integer number of spokes. More preferably, the spoke star has rotationally symmetrical sections, particularly sections each comprising two spokes.

[0023] A double-spoke design consists of two parallel spokes. Each spoke extends approximately parallel from the inner periphery of the spoke star on the hub side to the outer periphery of the spoke star on the rim side. The fiber orientation is reversed 180° by a loop on the outer periphery of the spoke star on the rim side. The fibers extend substantially parallel and in opposite directions in the two spokes of the double-spoke design.

[0024] The spoke star according to the invention can be manufactured by a wet winding method. Advantageously, the fiber type and plastic matrix can be matched to the requirements of the spokes. In a double-spoke configuration, the two spokes can be joined together via the plastic matrix during the manufacturing process of the spoke star.

[0025] Advantageously, the fibers are arranged in parallel within the spokes. This arrangement allows for optimal utilization of the fibers' stiffness and strength. In this way, material is saved when manufacturing the spoke star, which in turn advantageously reduces the weight of the spoke star. Thus, the goal of a lightweight structure is achieved not only through the use of carbon fiber with a low specific gravity but also through the most efficient use of materials possible.

[0026] The spoke star is continuously formed into a closed loop made of fiber composite material. Advantageously, the spoke star does not have open fiber bundles. This enables better load transfer within the spoke star.

[0027] Advantageously, the inner periphery of the spoke star on the hub side and the outer periphery of the spoke star on the rim side can have collars for connecting the spoke star to the hub or rim ring. These collars enable advantageous load transfer. The collars also allow the spoke star to be secured to bolts arranged on the hub, eliminating the need for additional fastening elements and resulting in weight savings.

[0028] When the outer periphery of the spoked star-shaped component on the rim side is designed as a collar, the collar preferably has half the diameter of the double spokes. Preferably, this reduces stress under the same tensile force.

[0029] Preferably, the two spokes of a double-spoke design can be joined together, resulting in a double-spoke design with a minimal cross-section in the direction of travel. Particularly preferably, the two spokes of a double-spoke design are arranged parallel to each other and staggered in the direction of travel. Advantageously, this arrangement of the spokes enables an aerodynamic shape. The shape of the double-spoke design can be advantageously modified during the manufacturing process of the spoke star using the mold cavity. Particularly advantageously, this allows for an elliptical design of the double-spoke design. This is particularly advantageous from an aerodynamic perspective.

[0030] The spoke arrangement within the spoke star can mimic the spoke arrangement of a traditional wheel with steel spokes. Here, the load transfer principles known from steel spokes can be used as the basis for the spoke arrangement. Advantageously, it is not necessary to implement new calculations, simulations, and experiments for load transfer in the spokes. Experience from traditional wheel rims can be used.

[0031] Advantageously, assembly is simplified by the spoke star according to the invention. Here, for each hub flange side, two identical spoke stars, twisted to each other, can be inserted into the hub. Here, the spoke star on the inner periphery of the spoke star on the hub side can be secured to the bolts of the hub by means of a collar. Here, the connection is preferably achieved through a form-fitting joint. Advantageously, the outer periphery of the spoke star on the rim side and the collar located at the rim side end of the double-spoke wheel point directly toward the rim hole of the rim ring, so as to secure and tension the spoke star on the rim ring. Particularly advantageously, the height impact and lateral impact of the spoked wheel, as well as centering, can be adjusted by tensioning the spoke star.

[0032] Particularly preferably, the spoke star component according to the invention enables particularly simple and quick replacement of damaged spoke star components. Therefore, in the event of a damaged spoke star component, only the spoke star component can be replaced instead of the entire spoked wheel. This reduces maintenance costs and enables resource-saving maintenance.

[0033] A preferred embodiment of the present invention is that at least one spoke has a fixing mechanism on its collar.

[0034] The retaining mechanism is used to secure the spoke star to the rim. The retaining mechanism can be inserted into the collar of the spoke star.

[0035] The fixing mechanism can be detachably connected to the wheel rim.

[0036] Suitable here is that the fixing mechanism can be connected to the collar in a form-fitting manner.

[0037] Particularly preferably, the connection between the spoke star and the fixing mechanism can be achieved through a form-fitting mechanism. Adhesion of the fixing mechanism is not required.

[0038] One design of the present invention is that the fixing mechanism is fixed to the rim ring by means of a threaded component.

[0039] Threaded fittings enable a particularly simple, quick, and reliable connection of the fixing mechanism to the rim. Advantageously, the spoke star can be pre-tensioned via the threaded fitting. By tensioning the spoke star, the height impact and lateral impact of the spoked wheel, as well as its centering, can be adjusted.

[0040] Threaded parts can be constructed as threaded parts with ball heads.

[0041] In this case, it is appropriate for the threaded parts to be aligned with the spokes.

[0042] For this purpose, the collar can be slightly bent out of the plane. Advantageously, the collar is additionally secured in the fixing mechanism by a form engagement via a threaded element. Advantageously, the threaded element prevents the collar from "jumping out" of the fixing mechanism.

[0043] The fixing mechanism also prevents the collar from being "pulled up." This is achieved by the "claws" of the fixing mechanism laterally supporting the collar outlet (Schlaufenauslauf).

[0044] It advantageously prevents bending moments on the spoke star. It is particularly advantageous for optimizing load transfer between the spoke star and the rim.

[0045] Finally, in another aspect of the invention, a spoked wheel is proposed, having a hub, a rim, and a plurality of spokes between the hub and the rim. This spoked wheel includes a spoke star-shaped element according to one of the foregoing embodiments.

[0046] The spoke star can be fixed to the rim and hub, thereby forming a spoked wheel. Here, the fixing of the spoke star to the hub can be achieved by a collar of the spoke star, which is bolted to the hub. The fixing of the spoke star to the rim can be achieved by means of a fixing mechanism according to the invention. Attached Figure Description

[0047] Exemplary embodiments of the invention are depicted in the accompanying drawings.

[0048] In the attached diagram:

[0049] Figure 1 A side view of a single spoked star-shaped member according to the invention is shown.

[0050] Figure 2 Two are shown Figure 1 A side view of the arrangement structure of the spoke star-shaped members according to the present invention.

[0051] Figure 3 Show a pair Figure 2 A top view of the layout structure.

[0052] Figure 4 A side view of the outer periphery of the spoked star-shaped member on the rim side according to the present invention is shown.

[0053] Figure 5 Show Figure 2 A side view of the inner periphery of the hub side of the wheel hub arrangement structure.

[0054] Figure 6 Show Figure 1A side view of the inner periphery of the spoked star-shaped component with a hub.

[0055] Figure 7 A perspective view of the outer periphery of the rim side of a spoked star-shaped member with a fixing mechanism according to the present invention is shown.

[0056] Figure 8 Show Figure 7 A side view of the outer periphery of the rim side of the spoked star-shaped component with a fixing mechanism.

[0057] Figure 9 Show Figure 7 A side view of the outer periphery of the spoked star-shaped component with a fixing mechanism on the rim side, in the state of being assembled onto the rim ring.

[0058] Figure 10 A side view of the hub according to the invention is shown.

[0059] Figure 11 , 11a Figures 11b and 11b show a perspective view of a wheel hub according to the invention before the fixed spoke star, the wheel hub having an assembled first spoke star and an assembled second spoke star. Detailed Implementation

[0060] Figures 1 to 3 An embodiment of the spoked star-shaped member 1 according to the present invention is schematically shown. Figure 1 A single spoked star-shaped piece 1 is shown. Figure 2 Two are shown in the middle. Figure 1 The arrangement of the spoke star-shaped components 1. Each spoke star-shaped component 1 is twisted 180° relative to each other. This arrangement can form one side of the spoke wheel. Figure 3 Two are shown in the middle. Figure 2 The arrangement of the two structures is slightly twisted relative to each other and forms the two sides of the spokes of the spoke wheel.

[0061] The spoke star 1 is made of a fiber-plastic composite material. The spoke star 1 has spokes 2 between its inner periphery on the hub side and its outer periphery on the rim side. In the spoke star 1, a single fiber bundle extends multiple times along the spokes 2 between the inner and outer peripheries. The spokes 2 are configured as double spokes. A double spoke consists of two parallel-extending spokes 2. Each spoke 2 extends substantially parallel from the inner periphery on the hub side to the outer periphery on the rim side. The spokes 2 have a collar 3 on the outer periphery on the rim side. Through the collar 3 on the outer periphery on the rim side, the fiber orientation is reversed by 180°. The fibers extend substantially parallel and in opposite directions in the two spokes 2 of the double spoke. A collar is provided on the inner periphery on the hub side for shaped-jointing the spoke star to the hub 7.

[0062] Figure 4 A detailed view of the outer periphery of the spoke star 1 on the rim side according to the invention is shown. The double spokes 2 have a collar 3 on the outer periphery of the spoke star on the rim side. Through the collar 3 on the outer periphery of the spoke star on the rim side, the fiber orientation is reversed by 180°. The fibers extend substantially parallel and in opposite directions in the two spokes 2 of the double spokes. Since the outer periphery of the spoke star is designed as a collar, the collar 3 has half the diameter of the double spokes 2.

[0063] exist Figure 5 The middle shows Figure 2 A detailed view of the inner periphery of the hub side of the arrangement structure. The spoke star can be connected to the hub 7 in a shaped engagement manner through a collar on the inner periphery of the hub side.

[0064] exist Figure 6 The middle shows Figure 1 A detailed view of the inner periphery of the hub side of a single spoke star 1. The spoke star is able to be shaped-fitted to the hub 7 by means of a collar on the inner periphery of the hub side.

[0065] Figure 7 and 8 A schematic diagram of a spoke star 1 with a fixing mechanism 4 according to the present invention is shown. The fixing mechanism 4 is inserted into a collar 3 located on the outer periphery of the spoke star on the rim side. In this way, the fixing mechanism 4 is shaped-fitted to the spoke star 1. The fixing mechanism 4 can be connected to the rim ring 6 by means of a threaded part 5. Figure 8 As can be seen, the collar 3 is slightly bent out of the plane. Thus, the collar 3 can be additionally fixed in the fixing mechanism 4 by form engagement via the threaded part 5, while the spoke star part 1 is in the assembled state. Advantageously, the threaded part 5 prevents the collar 3 from "jumping out" from the fixing mechanism 4.

[0066] exist Figure 9 The middle shows Figure 7 and Figure 8 The diagram shows the spoke star-shaped component 1 with fixing mechanism 4 mounted on the rim ring 6. Fixing mechanism 4 is secured to the rim ring 6 by threaded component 5. Here, the threaded component 5 additionally prevents the collar 3 from jumping out of the fixing mechanism 4 through a form engagement. Here, the threaded component 5 is aligned with the double spokes 2.

[0067] Figure 10 and 11 A schematic illustration shows a design of a hub 7 of a spoked wheel having a spoked star 1 according to the invention. The hub 7 has bolts 8 for shaped-fitting connection between the spoked star 1 and the hub 7, with the collar 3 of the spoked star 1 engaged in the bolts.

[0068] Here, bolt 8 is fitted into the collar on the inner periphery of the spoke star 1 on the hub side in the assembled state. Figure 11a and 11b The diagram shows how the first spoke star 1 is fixed to the inner periphery of the spoke star 1 on the hub side by first inserting the bolt 8 into the collar 3, and then the second spoke star 2 is fixed 180° away from it.

Claims

1. A spoked star-shaped component (1) made of a fiber-plastic composite, said spoked star-shaped component being constructed as a star-shaped closed loop, wherein, The spoke star (1) has at least two spokes (2) between the inner periphery on the hub side and the outer periphery on the rim side of the spoke star, wherein a single fiber bundle extends multiple times along the spokes (2) of the spoke star between the inner and outer peripheries, characterized in that the spokes (2) are constructed as double spokes, wherein the two spokes (2) of the double spokes are connected by a plastic matrix, and the spoke arrangement structure inside the spoke star (1) mimics a conventional wheel with steel spokes. The spoke arrangement structure wherein the spoke star (1) is continuously formed into a closed loop made of fiber composite material, wherein the spoke (2) has a collar (3) on the outer periphery of the spoke star on the rim side and a collar on the inner periphery of the spoke star on the hub side, wherein the collar on the inner periphery of the spoke star on the hub side enables the spoke star to be fixed to a bolt arranged on the hub, and the fibers extend substantially parallel and in opposite directions in the two spokes of the double spoke.

2. The spoke star-shaped component (1) according to claim 1, characterized in that, At least one spoke (2) has a fixing mechanism (4) on its collar (3).

3. The spoke star-shaped component (1) according to claim 2, characterized in that, The fixing mechanism (4) can be connected to the collar (3) in a shape-fitting manner.

4. The spoke star-shaped component (1) according to claim 2 or 3, characterized in that, The fixing mechanism (4) can be fixed to the rim ring (6) by means of the threaded part (5).

5. The spoke star-shaped component (1) according to claim 4, characterized in that, The threaded part (5) is aligned with the spoke (2).

6. A spoked wheel having a hub (7), a rim (6), and a plurality of spokes (2) between the hub (7) and the rim (6), characterized in that, The spoked wheel includes at least one spoked star (1) according to any one of claims 1 to 5.

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