Multi-composite material bicycle rim

Abstract

The invention relates to a multi-composite bicycle rim. A rim for a bicycle wheel includes a radially inner portion disposed along an inner circumference of the rim, a first sidewall, a second sidewall spaced apart from the first sidewall, a radially outer tire engaging portion disposed along an outer circumference of the rim, and an opening. The first sidewall, the second sidewall, the radially outboard tire engaging portion, the radially inboard portion, or any combination thereof, includes a composite laminate. A composite laminate includes one or more compressed layers of a first composite material and one or more compressed layers of a second composite material different from the first composite material, the first composite material including a matrix of a polymer-based material and natural fibers for reinforcing the material. The opening extends through at least one of the one or more compressed layers of the second composite material such that the second composite material surrounds the opening.

Description

Technical Field

[0001] The present disclosure relates generally to composite bicycle rims, and more particularly, to bicycle rims made from various composite materials, including natural fiber composites. Background Art

[0002] Conventional bicycle wheels may include a rim formed from extruded metal or other material that is bent and bonded into a circular shape having a uniformly formed cross-section. Recently, other materials such as fiber reinforced plastics have been used to manufacture bicycle rims, which can be formed into a circular shape by non-extrusion based processes. For example, carbon fiber reinforced plastics can be used.

[0003] Methods for making fiber-based bicycle wheels rely on stacking individual fiber composite sheets to form structures such as rim sidewalls. The fiber sheets may be pre-impregnated with a resin or other matrix material that undergoes a curing process to form the rim.

[0004] Openings may be formed through the rim structure. For example, holes may be drilled through the radially inner portion of the rim to form the spoke holes. The spoke holes are adjacent to the heavily prestressed area of ​​the rim. Therefore, any strength degradation at the spoke holes due to moisture may cause failure. Summary of the invention

[0005] In one example, a rim for a bicycle wheel includes a radially inner portion disposed along an inner circumference of the rim, a first sidewall, and a second sidewall spaced apart from the first sidewall. The first sidewall and the second sidewall extend radially outward from the radially inner portion. The rim also includes a radially outer tire engaging portion disposed along an outer circumference of the rim, the radially outer tire engaging portion extending from the first sidewall and the second sidewall, respectively; and an opening extending through the radially inner portion, the first sidewall, the second sidewall, the radially outer tire engaging portion, or any combination thereof. The first sidewall, the second sidewall, the radially outer tire engaging portion, the radially inner portion, or any combination thereof include a composite laminate. The composite laminate includes one or more compressed layers of a first composite material and one or more compressed layers of a second composite material. The second composite material is different from the first composite material and has a lower porosity than the first composite material. The first composite material includes a matrix of a polymer-based material and natural fibers for reinforcing material. The opening extends through at least one of the one or more compressed layers of the second composite material such that the second composite material surrounds the opening.

[0006] In one example, the polymer-based material is a thermoplastic, a thermosetting matrix or a combination thereof. The natural fibers of the reinforcing material are flax fibers.

[0007] In one example, the polymer-based material is a first polymer-based material, and the reinforcing material is a first reinforcing material. The second composite material includes a matrix of a second polymer-based material and fibers for a second reinforcing material. The second polymer-based material is plastic, acrylic, resin, epoxy, or any combination thereof. The fibers of the second reinforcing material are carbon fibers.

[0008] In one example, the opening is a first opening extending through the radially inner portion. The rim also includes a second opening extending through the radially outer tire engaging portion. The at least one layer of the second composite material is at least one first layer of the second composite material. The second opening extends through at least one second layer of the one or more compressed layers of the second composite material such that the second composite material surrounds the second opening.

[0009] In one example, the first opening is a spoke hole, a valve hole, or an opening capable of supporting electronic components of the bicycle. The second opening is an entry and exit hole.

[0010] In one example, the at least one first layer of the second composite material forms at least a portion of the radially inner portion, the portion of the radially inner portion extending around the entirety of the radially inner portion.

[0011] In one example, the at least one second layer of the second composite material forms at least a portion of the radially outer tire engaging portion, the portion of the radially outer tire engaging portion extending around the entirety of the radially outer tire engaging portion.

[0012] In one example, the opening is a first opening extending through the radially inner portion. The rim further comprises a second opening extending through the radially inner portion. The second opening is a distance away from the first opening along the radially inner portion.

[0013] In one example, the at least one layer of the second composite material is at least one first layer of the second composite material.The second opening extends through at least one second layer of the one or more compressed layers of the second composite material such that the second composite material surrounds the second opening.

[0014] In one example, at least one of the one or more compressive layers of the first composite material partially forms the radially inner portion. The at least one layer of the first composite material is disposed between the at least one first layer of the second composite material and the at least one second layer of the second composite material.

[0015] In one example, the first opening and the second opening are spoke holes, respectively.

[0016] In one example, a method of manufacturing a bicycle component includes positioning a layer of a first composite material within a mold. The first composite material includes natural fibers of a first reinforcing material. The method includes positioning a layer of a second composite material within the mold such that a portion of the layer of the second composite material abuts, overlaps, or abuts and overlaps the layer of the first composite material. The second composite material includes fibers of a second reinforcing material. The second reinforcing material is different from the first reinforcing material. The method includes forming the bicycle component. Forming the bicycle component includes forming a composite laminate within the mold including the layer of the first composite material and the layer of the second composite material. The method includes forming an opening of the layer of the second composite material through the composite laminate such that the second composite material surrounds the opening.

[0017] In one example, the natural fibers of the first reinforcement material are flax fibers. The fibers of the second reinforcement material are carbon fibers.

[0018] In one example, forming the opening through the layer of the second composite material of the composite laminate includes drilling the opening through the layer of the second composite material of the composite laminate.

[0019] In one example, the layer of the first composite material and the layer of the second composite material form a portion of a radially inner portion of the rim or a portion of a radially outer tire engaging portion of the rim, respectively.

[0020] In one example, the layer of the second composite material is a first layer of the second composite material, and the opening is a first opening. The method also includes positioning a second layer of the second composite material within the mold so that a portion of the second layer of the second composite material abuts, overlaps, or abuts and overlaps the layer of the first composite material, and the layer of the first composite material is located between the first layer of the second composite material and the second layer of the second composite material. The method also includes forming a second opening through the composite laminate. Forming the second opening includes forming the second opening through the second layer of the second composite material of the composite laminate so that the second composite material surrounds the second opening.

[0021] In one example, the bicycle component is a rim. The layer of the second composite material extends all around the rim and forms at least a portion of a radially inner portion disposed along an inner circumference of the rim or at least a portion of a radially outer tire engaging portion disposed along an outer circumference of the rim.

[0022] In one example, the layer of the second composite material is a first layer of the second composite material and forms at least a portion of the radially inner portion of the rim. The method further includes positioning the second layer of the second composite material within the mold such that the layer of the first composite material is between the first layer of the second composite material and the second layer of the second composite material. The second layer of the second composite material forms at least a portion of the radially outer tire engaging portion.

[0023] In one example, the layer of the first composite material forms at least a portion of a sidewall of the rim.

[0024] In one example, a rim for a bicycle wheel includes a radially inner portion disposed along an inner circumference of the rim, a first sidewall, and a second sidewall spaced apart from the first sidewall. The first sidewall and the second sidewall extend radially outward from the radially inner portion. The rim includes a radially outer tire engaging portion disposed along an outer circumference of the rim. The radially outer tire engaging portion extends from the first sidewall and the second sidewall, respectively. The rim includes a plurality of openings extending through the radially inner portion. The plurality of openings are spoke holes and are spaced apart from each other around the radially inner portion. At least the radially inner portion includes a composite laminate. The composite laminate includes one or more compressed layers of a first composite material and one or more compressed layers of a second composite material. The second composite material is different from the first composite material and has a lower porosity than the first composite material. The compressed layers of the first composite material and the compressed layers of the second composite material are each composed of strip plies of a corresponding composite material. The first composite material includes a matrix of a polymer-based material and natural fibers for reinforcing material. The plurality of openings extend through at least one of the one or more compressed layers of the second composite material such that the second composite material surrounds the plurality of openings.

[0025] In one example, strip plies of the first composite material overlap strip plies of the second composite material.

[0026] In one example, strip plies of the first composite material are interleaved with strip plies of the second composite material. BRIEF DESCRIPTION OF THE DRAWINGS

[0027] The objects, features and advantages of the present invention will become clear after reading the following description taken in conjunction with the accompanying drawings, in which:

[0028] Figure 1 is a schematic side view of a bicycle that may be configured to utilize a composite rim;

[0029] Figure 2 Such as Figure 1 A side view of a wheel of such a bicycle;

[0030] Figure 3 is a first perspective view of a first embodiment of a composite rim formed from layers of multiple composite materials;

[0031] Figure 4 yes Figure 3 A second perspective view of the composite rim;

[0032] Figure 5 yes Figure 3 A side view of a composite rim;

[0033] Figure 6 It is taken along axis 6-6 Figure 5 A first cross-section of a composite rim;

[0034] Figure 7 It is taken along axis 7-7 Figure 5 a second cross-section of the composite rim;

[0035] Figure 8 Can be used in Figure 3 A top view of a first type of strip in a layup of a composite rim;

[0036] Fig. 9 Can be used in Figure 3 A top view of a second type of strip in a stack of composite rims;

[0037] Fig.10 is a first perspective view of a second embodiment of a composite rim formed from layers of multiple composite materials;

[0038] Fig.11 yes Fig.10 A second perspective view of the composite rim;

[0039] Fig.12 yes Fig.10 A side view of a composite rim;

[0040] Fig.13 It is taken along the axis 13-13 Fig.12 A first cross-section of a composite rim;

[0041] Fig.14 It is taken along the axis 14-14 Fig.12 a second cross-section of the composite rim;

[0042] Fig.15 is a perspective view of a third embodiment of a composite rim formed from layers of multiple composite materials;

[0043] Fig.16 is a flow chart of an embodiment of a method for manufacturing a wheel rim;

[0044] Fig.17 It is taken along axis 6-6 Figure 5 Embodiments of the cross section of the composite rim;

[0045] Fig.18 It is taken along axis 7-7 Figure 5 Embodiments of the cross section of the composite rim;

[0046] Fig.19 It is taken along axis 6-6 Figure 5Alternative embodiments of the cross-section of the composite rim;

[0047] Fig. 20 It is taken along axis 7-7 Figure 5 Alternative embodiments of the cross-section of the composite rim;

[0048] Fig.21 Shown in Figure 5 The overlap configuration used in the rim of the wheel; and

[0049] Fig. 22 Shown in Figure 5 The staggered configuration used in the rims. DETAILED DESCRIPTION

[0050] Compared to traditional bicycle rims formed from extruded metal or other materials, using, for example, carbon fiber sheets or strips to manufacture prior art composite rims provides a number of advantages. For example, carbon fiber-based bicycle rims have high tensile strength, low weight, and low thermal expansion compared to traditional bicycle rims.

[0051] However, carbon fiber composite bicycle parts have a high specific stiffness, which in some applications can be detrimental to the bicycle rider. This can lead to undesirable energy loss from the vehicle due to vibrations transmitted from road irregularities through the bicycle's components to the rider. This can cause physiological fatigue and compensation for the rider. Carbon is also an electrical conductor that can shield wireless signals used by the bicycle's electronic components. Therefore, carbon fiber can act as a Faraday cage that blocks wireless signals.

[0052] The present disclosure provides examples of bicycle parts such as rims and wheels made from thin layers of low-density cellulose composites (e.g., flax composites) that solve or improve upon one or more of the above and / or other disadvantages associated with bicycle parts made entirely from carbon fiber composites or other non-traditional materials. For example, the disclosed rims made at least in part from flax composites provide excellent vibration damping, sound attenuation, and more ductile failures while maintaining a unique balance between stiffness, weight, and processability. For example, the disclosed rims can also be at least partially non-conductive, thereby allowing wireless signals to pass through. The ability to be processed like a carbon fiber composite provides that cellulose fiber composites (e.g., flax composites) can also be used in hybrid layups with carbon and / or other engineered fibers.

[0053] However, rims and wheels made from flax composites may not perform well in wet conditions. For example, paint, additional resin films or barrier plies may be used on the surface to seal large portions of flax composite wheels. For example, holes cut or drilled through the rim (e.g., laminate) to form spokes and access holes expose the fibers to the elements and may be difficult to maintain a seal due to wear. The spoke holes are also adjacent to some areas of the heavy-load prestressed areas of the rim. Therefore, any strength degradation at the spoke holes due to moisture may cause failure.

[0054] For example, by using inherently solid and non-moisture wicking materials at the drilled holes in the rim, moisture degradation at the drilled holes can be reduced or prevented (e.g., the drilled holes can remain sealed). For example, a fully sealed rim can be provided with a laminate in which natural fibers (e.g., flax fibers) are used in easy-to-seal locations and other materials (e.g., materials that do not wick or absorb water or moisture, such as carbon fiber and / or fiberglass) are used in difficult-to-seal locations. Difficult-to-seal locations can include, for example, spoke holes, inlet and outlet holes, valve holes, and other holes / openings that support sensors and electronics.

[0055] As an example, for a wheel having spokes or nipples extending through holes in a laminate forming the innermost surface of the rim (e.g., the radially inner portion of the rim), the laminate may include, for example, carbon or glass fibers around the holes. This may be provided by replacing the natural fibers in the laminate around the holes with an alternative material (e.g., carbon or glass fibers), arranging patches comprising the alternative material at the holes, respectively, or arranging a fully circumferential ply of the alternative material at the radially inner portion of the rim.

[0056] As another example, for a rim having an access hole (e.g., in the radially outer tire engaging portion of the rim) for lacing, trimming, or repairing the wheel, the laminate may include, for example, carbon or glass fibers around the access hole. This may be provided by replacing the natural fibers in the laminate around the access hole with an alternative material (e.g., carbon or glass fibers), placing patches comprising the alternative material at the access hole, respectively, or placing a full circumferential ply comprising the alternative material at the radially outer tire engaging portion of the rim.

[0057] As yet another example, electronics or other devices may be housed within a cavity formed in the rim, and the cavity (e.g., at a hole or pocket) may be sealed by utilizing an inherently sealed laminate including, for example, carbon or glass fibers surrounding the cavity. This may be provided locally to avoid reducing the transmission rate of radio waves through the natural fiber laminate for wireless electronics.

[0058] Composite materials may require deburring or removal of unwanted resin from the molding process. This process may expose the fibers and, for example, carbon fiber, fiberglass or other inherent sealing materials may be used locally to seal the laminate.

[0059] For example, natural fiber (e.g., flax fiber) and carbon fiber composite rims (e.g., flax carbon hybrid rims) can be made using common manufacturing processes used to make carbon composite bicycle parts such as rims. For example, manufacturing processes such as press curing, autoclave curing, oven curing, and / or resin transfer molding can be used. Flax carbon hybrid rims can also be formed using materials such as bladders or materials that apply pressure to the laminate due to thermal growth (e.g., silicone in a confined molding tool).

[0060] Natural fiber composites have a favorable combination of low material density, a suitable range of specific stiffness, and signal transmission properties. An advantage of using the disclosed natural fiber composites for bicycle parts is that the weight of the bicycle parts can be reduced for a structure that does not rely heavily on the tensile strength of specific fibers. Another advantage is increased vibration damping in the bicycle parts, thereby reducing motorcycle energy losses while increasing comfort and control. Other advantages are reduced noise from bicycle parts due to increased sound attenuation and the generation of more ductile failure responses, which results in less catastrophic failures often associated with carbon composites.

[0061] The disclosed laminate includes both a natural fiber composite and an inherently solid and non-hygroscopic composite. The natural fiber composite can be used in easy-to-seal areas of the rim (e.g., sidewalls that do not include any openings or holes), and the inherently solid and non-hygroscopic composite can be used in difficult-to-seal areas of the rim (e.g., at holes through the radially inner portion of the rim and / or the radially outer tire-engaging portion of the rim). Such a laminate includes the benefits of natural fiber composites (e.g., a favorable combination of low material density, an appropriate range of signal stiffness, and signal transmission properties) while preventing or mitigating moisture degradation.

[0062] Now turning to the attached figure, Figure 1A bicycle 50 is generally illustrated that employs rims constructed in accordance with the teachings of the present disclosure. The bicycle 50 includes a frame 52, a front wheel 54 and a rear wheel 56 rotatably attached to the frame 52, and a drive train 58. A front brake 60 is provided for braking the front wheel 54, and a rear brake 62 is provided for braking the rear wheel 56. The bicycle 50 also typically has a seat 64 located near the rear end of the frame 52 and carried on the end of a seat post 66 connected to the frame 52. The bicycle 50 also has a handlebar 68 located near the forward end of the frame 52. A brake lever 70 is carried on the handlebar 68 for actuating the front brake 60, the rear brake 62, or both the front brake 60 and the rear brake 62. If the brake lever 70 actuates only one of the front brake 60 and the rear brake 62, a second brake lever (not shown) for actuating the other brake may also be provided. Figure 1 The direction of arrow A in FIG. 5 indicates the front and / or forward riding direction or orientation of bicycle 50. Thus, the forward direction of bicycle 50 is indicated by the direction of arrow A. Figure 1 The exemplary bicycle 50 depicted in FIG. 5 is a road bicycle having a dropped handlebar 68 , but the present disclosure may be applicable to any type of bicycle, including mountain bicycles having full or partial suspension.

[0063] The transmission system 58 has a chain C and a front sprocket assembly 72 mounted coaxially with a crank assembly 74 having a pedal 76. The transmission system 58 also includes a rear sprocket assembly 78 mounted coaxially with the rear wheel 56 and a rear gear changing mechanism such as a rear derailleur 80.

[0064] like Figure 1 As shown in the example, the front sprocket assembly 72 may include one or more coaxially mounted chain rings, gears or sprockets. In this example, the front sprocket assembly 72 has a sprocket F. The sprocket F has teeth 82 around a corresponding circumference. Figure 1As shown in , the rear sprocket assembly 78 may include a plurality of coaxially mounted gears, cogs or sprockets G. Each sprocket G1-G11 also has teeth 84 arranged around a corresponding circumference. The number of teeth 84 on the rear sprockets G1-G11 may gradually decrease from the rear sprocket G1 of the largest diameter to the sprocket G1 of the smallest diameter. Although not described in any detail herein, the front gear changer 85 may be operated to move from a first operating position to a second operating position, thereby moving the chain C between the front sprockets F. Similarly, the rear derailleur 80 may be operable to move between different operating positions, thereby switching the chain C to a selected one of the rear sprockets G1-G11. In one embodiment, the rear sprocket assembly 78 may have more or fewer sprockets G. For example, in one embodiment, the rear sprocket assembly 78 may have twelve or thirteen sprockets. The size and configuration of the rear derailleur 80 may be modified to accommodate multiple sprockets of a particular implementation. For example, the angle and length of the linkage of the rear derailleur 80 and / or the configuration of the cage of the rear derailleur 80 may be modified to accommodate a particular sprocket combination.

[0065] The rear derailleur 80 is depicted as a wireless, electrically actuated rear derailleur mounted or mountable to the frame 52 or a frame accessory of the bicycle 50. The electric rear derailleur 80 has a base member 86 (e.g., a b-type knuckle) mounted to the bicycle frame 52. A linkage 88 has two links L pivotally connected to the base member 86 at a base member linkage connection portion. A movable member 90 (e.g., a P-type knuckle) is connected to the linkage 88 at a movable member linkage connection portion. A chain guide assembly 92 (e.g., a cage) is configured to engage and maintain tension in the chain and has one or more cage plates 93 having a proximal end pivotally connected to a portion of the movable member 90. The cage plates 93 can rotate or pivot about the cage rotation axis in a damping direction and a chain tensioning direction. Other gear changing systems such as mechanically or hydraulically controlled and / or actuated systems may also be used.

[0066] The motor module can be carried on the electric rear derailleur 80 together with the battery. The battery supplies power to the motor module. In one example, the motor module is located in the movable member 90. However, the motor module can be located elsewhere instead, such as in one of the connecting rods L of the linkage 88 or in the base member 86. The motor module may include a gear mechanism or transmission. As known in the art, the motor module and the gear mechanism can be coupled to the linkage 88 to move the cage plate 93 laterally and thus switch the chain C between the rear sprockets (e.g., G1-G11) on the rear sprocket assembly 78.

[0067] The retainer plate 93 also has a distal end that carries a tensioning cogwheel or tensioning wheel. The tensioning wheel also has teeth around the circumference. The retainer plate 93 is biased in the chain tensioning direction to maintain tension in the chain C. The chain guide assembly 92 may also include a second cogwheel or a second wheel such as a guide wheel disposed closer to the movable member 90 and the proximal end of the retainer plate 93. In operation, the chain C is laid around one of the rear sprockets (e.g., G1-G11). The upper section of the chain C extends forward to the front sprocket assembly 72 and is laid around a front sprocket F. The lower section of the chain C returns from the front sprocket assembly 72 to the tensioning wheel and is then laid forward to the guide wheel. The guide wheel guides the chain C to the rear sprocket (e.g., G1-G11). The lateral movement of the retainer plate 93, the tensioning wheel, and the guide wheel can determine the lateral position of the chain C aligned with a selected one of the rear sprockets (e.g., G1-G11).

[0068] The bicycle 50 may include one or more bicycle control devices mounted to the handlebars 68. The bicycle control device may include one or more types of bicycle controls and / or actuation systems. For example, the bicycle control device may include a brake actuation system for controlling the front brake 60 and / or the rear brake 62 and / or a shifting system for controlling the transmission 58. Other control systems may also be included. For example, in some embodiments, these systems may be applied to bicycles in which only a front gear shifter or only a rear gear shifter is used. In addition, the one or more bicycle control devices may also include a suspension, a seat post, and / or other control systems for the bicycle 50.

[0069] The front wheel 54 and / or the rear wheel 56 of the bicycle 50 may include a tire 120 attached to a radially outer tire engaging portion of a rim 122. Figure 1 and Figure 2 As shown in FIG. 1 , a plurality of spokes 124 are directly attached to the rim 122. Alternatively, the spokes 124 may be attached and / or secured to the rim 122 with other structural members. The spokes 124 extend from the rim 122 and are attached to a central hub 126. The spokes 124 are held in tension between the rim 122 and the central hub 126 to provide operational rigidity for the respective wheels 54, 56 for use on the bicycle 50. The central hub 126 is configured to be rotatably attached to the bicycle frame 52.

[0070] Figure 2 A bicycle wheel having a rim 122, spokes 124, and a central hub 126 is illustrated, such as removed from the rest of the bicycle 50 and without a tire attached. Figure 1 The front wheel 54. The rim 122 includes a tire engaging portion 130 for engaging with the tire 120, such as Figure 1. The tire engaging portion 130 is configured to be located radially outward of the spoke receiving surface 132 disposed along the inner circumference 134 of the rim 122. In other words, the tire engaging portion 130 is a radially outward tire engaging portion. In one embodiment, the tire engaging portion 130 is disposed along the outer circumference 135 of the rim 122. The tire engaging portion 130 is configured to be attached to the tire using a clincher-type tire attachment configuration including a tire with a bead interlocking attachment. Other configurations of the tire engaging portion 130 may also be provided to allow other types of tires to be used on the rim 122. For example, a tubeless tire including a bead interlocking attachment type may be used.

[0071] The rim 122 provides structure for attaching the spokes 124 to the rim 122 at a receiving portion of the rim 122 proximate the spoke receiving surface 132. As such, the spoke receiving surface 132 is a portion of a spoke engaging portion 136 (e.g., a radially inner portion) of the rim 122. In one embodiment, the spoke engaging portion 136 of the rim 122 is disposed along an inner circumference 134 of the rim 122. In another embodiment, the spoke receiving surface 132 and the spoke engaging portion 136 can be separate parts and / or portions of the rim 122. For example, the spokes 124 can pass through the spoke receiving surface 132, and the structure for attaching to the rim 122 can be disposed proximate the tire engaging portion 130.

[0072] The rim 122 includes a first sidewall 138 and a second sidewall extending between the tire engaging portion 130 and the spoke engaging portion 136. For example, the first sidewall 138 and the second sidewall extend radially outward from the spoke engaging portion 136 to the tire engaging portion 130. The first sidewall 138 is spaced apart from the second sidewall.

[0073] At least a portion of the rim 122 (e.g., the spoke engaging portion 136 and / or the tire engaging portion 130) is formed of one or more composite materials. In one embodiment, the entire rim 122 is formed of two or more composite materials. Other configurations may also be provided. For example, a combination of natural fiber reinforced plastic and carbon fiber reinforced plastic forms a one-piece, integral rim that includes a collection of natural fiber layers and carbon fiber layers of the tire engaging portion 130, the first sidewall 138, the second sidewall, and the spoke engaging portion 136.

[0074] The front wheel 54 and the rear wheel 56 may include a rim 122 configured for use with any size wheel. In one embodiment, the rim 122 is configured for use with a wheel conforming to the 700C (e.g., 622 mm diameter clincher and / or ISO 622 mm) bicycle wheel standard.

[0075] The front wheels 54 and rear wheels 56 can rotate in either direction about the central hub 126. For example, Figure 2 As shown in , the front wheels 54 and the rear wheels 56 can be configured to rotate in a specific rotational direction around the central hub 126. In another example, the front wheels 54 and the rear wheels 56 can be configured to rotate in a direction opposite to the specific rotational direction.

[0076] In one embodiment, the front wheel 54 and / or the rear wheel 56 (e.g., Figure 1 The first sidewall 138, the second sidewall, the spoke engagement portion 136, and the tire engagement portion 130 of the front wheel 54 and the rear wheel 56 in the example of FIG. 1 are at least partially formed by one or more layers (e.g., layers of composite materials) of one or more composite materials. Each of the one or more layers may include one or more fabric plies (e.g., fragments) of the corresponding composite material. Different layers of different composite materials may include different numbers of composite material plies or fragments, respectively. At least some of the layers of composite materials may have different shapes and / or sizes. Alternatively, all of the layers of composite materials may be the same shape and / or size.

[0077] In one embodiment, at least some of the layers of composite material are formed into strips. For example, the strips of one or more composite materials may form the first side wall 138 and the second side wall of the front wheel 54. The strips of one or more composite materials may be disposed around the central hub 126 of the front wheel 54 and the central hub 126 of the rear wheel 56, respectively, to form the first side wall 138 and the second side wall of the front wheel 54 and the rear wheel 56, respectively.

[0078] In the manufacturing process, the layers of the front wheel 54 and the rear wheel 56 are integrated with the spoke engaging portion 136 and the tire engaging portion 130 (e.g., the composite material layers forming the spoke engaging portion 136 and the tire engaging portion 130) of the respective wheels 54, 56, such as by a curing process, so as to form a one-piece integral rim 122. The rims 122 of the front wheel 54 and the rear wheel 56 may be formed separately using other manufacturing processes.

[0079] Figures 3 to 7 A first embodiment of a composite rim 200 formed from layers of multiple composite materials is shown. A layup pattern of layers of composite material for the rim is provided prior to a curing process, for example to form the rim 200. After the curing process, the layers of multiple composite materials may be part of a one-piece integral rim 200. The resulting one-piece integral rim 200 may be formed from a composite laminate including one or more compressed layers of one or more composite materials.

[0080] Any number of composite materials may be included in the composite laminate. For example, one or more composite materials of the composite laminate may include a first composite material, a second composite material, a third composite material, or any combination thereof. The composite laminate may include more or fewer composite materials. For example, the composite laminate may include only a first composite material and a second composite material, or may include only a second composite material and a third composite material.

[0081] Many natural fibers offer a combination of low material density (e.g., compared to fiberglass) and a sufficient range of specific stiffness for many different types of bicycle components (e.g., bicycle rims, crank arms, handlebars, stems, seat posts, seat rails, shifters, brake levers, derailleur cages, suspension fork components). For example, flax has a specific stiffness of less than 1.5 g / cm 3 Density (e.g., greater than 2.5 g / cm2 compared to glass fiber) 3 Compared with the density of 3 ) specific modulus (e.g., compared to 28 GPa / (g / cm 3 ) and 500MPa / (g / cm 3 )'s ultimate specific strength (e.g., compared to glass fiber's 1,390 MPa / (g / cm 3 As another example, cannabis has a mass fraction of less than 1.5 g / cm 3 Density, 30GPa / (g / cm 3 ) and a specific modulus of 372MPa / (g / cm 3 )'s ultimate specific strength.

[0082] The combination of cellulose structure and unique specific stiffness properties, specific modulus properties, and processability characteristics damps vibrations, increases sound attenuation, and provides more ductile failures compared to composite materials used in the prior art (e.g., fiberglass). Unlike carbon fiber composites that act as a Faraday cage that blocks signals, low-density cellulose composites (e.g., flax fiber composites) are non-conductive, allowing electrical signals to pass through the composite.

[0083] Reference Figure 3 , Figure 6 and Figure 7 , the composite rim 200 includes a radially outer tire engaging portion 202 (e.g., disposed along the outer circumference of the composite rim 200), a radially inner portion 204 (e.g., a spoke engaging portion), a first sidewall 206, and a second sidewall 208 spaced apart from the first sidewall 206. The first sidewall 206 and the second sidewall 208 extend radially outward from the radially inner portion 204 to the radially outer tire engaging portion 202. The radially outer tire engaging portion 202 extends from the first sidewall 206 to the second sidewall 208, respectively.

[0084] The radially outer tire engaging portion 202 of the composite rim 200 includes a first tire retaining portion 210 and a second tire retaining portion 212 spaced apart from the first tire retaining portion 210. The first tire retaining portion 210 extends from the first sidewall 206 and the second tire retaining portion 212 extends from the second sidewall 208.

[0085] The first tire retaining portion 210 includes a first tire retaining wall 214. In one embodiment, the first tire retaining portion 210 also includes a first protrusion (e.g., a first tire retaining feature) (not shown). The first protrusion can extend away from the first tire retaining wall 214. The first protrusion can have any number of shapes, including, for example, a rectangular cross-section with a semi-circular cap. The first protrusion can extend circumferentially around the composite rim 200.

[0086] The second tire retaining portion 212 includes a second tire retaining wall 216. The second tire retaining wall 216 is opposite and spaced from the first tire retaining wall 214. In one embodiment, the second tire retaining portion 212 also includes a second protrusion (e.g., a second tire retaining feature) (not shown). The second protrusion can extend away from the second tire retaining wall 216 toward the first tire retaining portion 210. The second protrusion can have any number of shapes, including, for example, a rectangular cross-section with a semicircular cap. The second protrusion can extend circumferentially around the composite rim 200. The first protrusion and the second protrusion can have other shapes.

[0087] The composite rim 200 can accommodate a tire 120 (see Figure 1 ), i.e., for example, a tubeless clincher tire. Tire 120 includes a bead that interacts with radially outer tire engaging portions 202 (e.g., first tire retaining portions 210 and second tire retaining portions 212) of composite rim 200 to attach tire 120 to composite rim 122 and retain tire 120 on composite rim 122. The bead may include, for example, steel wire or aramid (e.g., Kevlar) within the bead. TM ) fibers to prevent the tire 120 from moving out of the composite rim 200. TM The fibers are reinforced and the beads resist stretching due to internal air pressure. Alternatively, the beads may be made of the same material as the tire 120 (eg, rubber).

[0088] The radially outer tire engaging portion 202 also includes a well 218 positioned between the first tire retaining portion 210 and the second tire retaining portion 212 of the composite rim 200. The well 218 provides a volume in which the beads of the tire 120 can be placed when the tire 120 is being attached to the composite rim 200. As the tire 120 is inflated, the beads of the tire 120 move away from each other until the beads interact with the first tire retaining portion 210 and the second tire retaining portion 212, respectively. When inflated, the beads of the tire 120 abut the first tire retaining wall 214 and the second tire retaining wall 216, respectively. In one embodiment, the first tire retaining feature and the second tire retaining feature, for example, retain the beads of the tire 120 positioned within the radially outer tire engaging portion 202 (e.g., retain the beads of the tire 120 engaged with the first tire retaining wall 214 and the second tire retaining wall 216), thereby preventing the tire 120 from being blown off the composite rim 200. The contact between the beads and first and second tire retaining walls 214 , 216 , respectively, forms a seal between the inflated tire 120 and the composite rim 200 .

[0089] The radially outer tire engaging portion 202 may also include ridges (e.g., bead projections; first bead projections and second bead projections) located on opposite sides of the groove 218, respectively. A first shelf 220 (e.g., first bead shelf) extends away from the first tire retaining wall 214 (e.g., between the first tire retaining wall 214 and the first bead projection), and a second shelf 222 (e.g., second bead shelf) extends away from the second tire retaining wall 216 (e.g., between the second tire retaining wall 216 and the second bead projection). In one embodiment, a curved transition region 224 extends between the first shelf 220 and the first tire retaining wall 214 and between the second shelf 222 and the second tire retaining wall 216, respectively. The bead projections may be located on opposite sides of the groove 218, respectively, and may be elevated relative to the first shelf 220 and the second shelf 222, respectively. If the tire 120 loses pressure, the bead projections may help retain the tire 120 on the composite rim 200.

[0090] Reference Figures 3 to 7 , at least a portion of the first sidewall 206 and a portion of the second sidewall 208 may be made of the first composite material. In one embodiment, at least a portion of the radially outer tire engaging portion 202 (e.g., the first tire retaining portion 210 and the second tire retaining portion 212) is also made of the first composite material. In one embodiment, at least a portion of the radially inner portion 204 is made of the first composite material.

[0091] The first composite material may include a matrix of a first polymer-based material and natural fibers of a first reinforcing material. In one example, the first reinforcing material has a strength of 24 GPa / (g / cm 3 ) and 60GPa / (g / cm 3 ) and below 600MPa / (g / cm 3 ). Alternatively, or in addition, the first reinforcement material can have a cellulose content greater than 40% and a hemicellulose content greater than 4%. The first polymer-based material can be any number of materials, including, for example, a thermoplastic, a thermosetting matrix, another polymer-based material, or any combination thereof, and the natural fibers of the first reinforcement material can be any number of materials, including, for example, flax fibers. Other reinforcement materials can be used. For example, in other embodiments, kenaf fibers, hemp fibers, jute fibers, sisal fibers, one or more other natural fibers, or any combination thereof can be used.

[0092] Figure 8 An embodiment of a layer 250 of a first composite material formed into a strip is illustrated. The first composite material includes a matrix 252 of a polymer-based material (e.g., a first polymer-based material) and fibers 254 of a reinforcing material (e.g., a first reinforcing material). In one embodiment, the first polymer-based material is, for example, a thermoplastic or a thermoset. In one embodiment, the fibers 254 of the first reinforcing material are, for example, flax fibers. Other polymer-based materials and / or other reinforcing fibers may be used.

[0093] The fibers 254 extend along a finite length L of the strip 250. In one embodiment, the fibers 254 extend in a primary strength direction of the strip 250 (e.g., along the length L of the strip 250). For example, the strip 250 has a unidirectional fiber orientation along the length L. In another embodiment, some of the fibers 254 do not extend in the primary strength direction (e.g., less than 20% of the fibers, less than 10% of the fibers, or less than 5% of the fibers).

[0094] The strip 250 can have any number of shapes and / or sizes. For example, the shape of the strip 250 is rectangular. Other shapes such as (for example) square strips and non-rectangular parallelogram strips can be provided. The strip 250 also includes a width W perpendicular to the length L. The length L can be defined by, for example, the size of the radially outer tire engaging portion 202, the first sidewall 206, the second sidewall 208, and / or the radially inner portion 204 of the composite rim 200. In other words, the length L can be at least as high or as wide as the radially outer tire engaging portion 202, the first sidewall 206, the second sidewall 208, and / or the radially inner portion 204 of the composite rim 200. In one embodiment, the width W of the strip 250 is between 10 mm and 50 mm. For example, the width W of the strip 250 is 30 mm. In other embodiments, the strip 250 is wider or narrower (for example, 60 mm). Smaller strip widths better optimize fiber orientation, but at the expense of increased manufacturing complexity. In one embodiment, the width W of the strip 250 is as wide as the radial width of the composite rim 200 .

[0095] Layers 250 of different shapes, greater widths, and / or greater lengths may be used. For example, at least some of the layers of the first composite material(s) may extend a quarter, half, or all the way around the rim. Depending on the application within the rim (e.g., forming an outer surface, providing strength and stiffness at high load locations within the rim), layers of the first composite material of different sizes and / or shapes may be used.

[0096] The layer 250 of the first composite material can have any number of thicknesses. For example, the thickness of the layer 250 of the first composite material can be 0.4 mm or thinner (e.g., 0.25 mm or thinner). Other thicknesses of the layer 250 of the first composite material can be provided.

[0097] For example, layer 250 provides ultimate strength in the direction of the fiber particles. Thus, fiber alignment relative to the inner diameter of composite rim 200 can be provided to increase the strength of composite rim 200. The width W of layer 250 is a variable that maximizes fiber alignment relative to a specified orientation. The farther the fiber is from the center of composite rim 200, the greater the change in the fiber angle relative to the tangent of the rim, thereby reducing the fiber's ability to withstand stress and loads.

[0098] Reference Figures 3 to 7, at least a portion of the first sidewall 206 and a portion of the second sidewall 208 may be made of the first composite material. At least a portion of the radially outer tire engaging portion 202 (e.g., the groove 218, the first shelf 220 and the second shelf 222) and at least a portion of the radially inner portion 204 of the composite rim 200 may be made of the second composite material. In one embodiment, at least a portion of the first sidewall 206 and / or at least a portion of the second sidewall 208 are also made of the second composite material.

[0099] In one embodiment, the layer of the second composite material is formed into a strip. The strip of the second composite material may be similar to Figure 8 250 of the first composite material shown in FIG. For example, the second composite material also includes a matrix of a polymer-based material (e.g., a second polymer-based material) and fibers of a reinforcing material (e.g., a second reinforcing material). The second polymer-based material can be any number of materials, including, for example, plastic, acrylic, resin, epoxy, or any combination thereof, and the fibers of the second reinforcing material can be any number of materials, including, for example, carbon. Other polymer-based materials and / or other reinforcing fibers can be used.

[0100] Compared to the first reinforcement material, the second reinforcement material can be denser and can have a greater specific modulus and specific ultimate strength. For example, carbon has a specific modulus of more than 2.5 g / cm 3 The density is 162GPa / (g / cm 3 ) and a specific modulus of 2,952MPa / (g / cm 3 ). Although carbon is heavier than the first reinforcement material, carbon and / or other denser but stronger reinforcement materials can be used to reinforce specific areas of the rim and prevent or reduce strength degradation of the composite rim 200 (e.g., at the radially inner portion 204 of the composite rim 200). In one embodiment, the second composite material has a lower porosity than the first composite material and / or the third composite material.

[0101] Similar to Figure 8 254, the fibers of the second reinforcement material can extend along a limited length of the strip. In one embodiment, the fibers of the second reinforcement material extend in the main strength direction of the strip. For example, the strips of the second composite material have a unidirectional fiber orientation along the length of the strip. In another embodiment, some of the fibers of the second reinforcement material do not extend in the main strength direction (e.g., less than 20% of the fibers, less than 10% of the fibers, or less than 5% of the fibers).

[0102] The strips of the second composite material can have any number of shapes and / or sizes. For example, the shape of the strips of the second composite material is rectangular. Other shapes such as (for example) square strips and non-rectangular parallelogram strips can be provided.

[0103] The strip of the second composite material also includes a width W perpendicular to the length L. The width W can be defined by, for example, the size of the radially inner portion 204 of the composite rim 200. In one embodiment, the width W of the strip of the second composite material is between 10 mm and 50 mm. For example, the width W of the strip of the second composite material is 30 mm. In other embodiments, the strip of the second composite material is wider or narrower. The strip of the second composite material can have any number of thicknesses.

[0104] Layers of the second composite material of different shapes, greater widths and / or greater lengths may be used. For example,

[0105] At least some of the layers of the second composite material may extend one quarter, half, or all the way around composite rim 200 (e.g., as part of radially inner portion 204). Depending on the application within composite rim 200 (e.g., providing strength and stiffness at high load locations within the rim), layers of the second composite material of different sizes and / or shapes may be used.

[0106] In one embodiment, at least a portion of radially outer tire engaging portion 202 (eg, first tire retaining portion 210 and second tire retaining portion 212) is also made of a third composite material. In one embodiment, at least a portion of radially inner portion 204 is made of a third composite material.

[0107] The third composite material may include a matrix of a third polymer-based material and natural fibers of a third reinforcing material. In one example, the third reinforcing material has a strength of 24 GPa / (g / cm 3 ) and 60GPa / (g / cm 3 ) and below 600MPa / (g / cm 3 ) of specific strength. Alternatively, or in addition, the third reinforcement material can have a cellulose content greater than 40% and a hemicellulose content greater than 4%. The third polymer-based material can be any number of materials, including, for example, resins, epoxy resins, or any combination thereof, and the natural fibers of the reinforcement material can be any number of materials, including, for example, flax fibers. Other natural fibers of reinforcement materials such as (for example) kenaf fibers, hemp fibers, jute fibers, sisal fibers, one or more other natural fibers, or any combination thereof can be used. In one embodiment, the third reinforcement material is the same as the first reinforcement material (e.g., flax).

[0108] Fig. 9 An embodiment of a layer 260 of a third composite material formed into a strip is illustrated. The third composite material includes a matrix 262 of a polymer-based material (e.g., a third polymer-based material) and fibers 264 of a reinforcing material (e.g., a third reinforcing material). In one embodiment, the third polymer-based material is a resin and the fibers of the third reinforcing material are flax fibers.

[0109] The fibers 264 are woven within a matrix 262 of a polymer-based material of the strip 260. Accordingly, at least some of the fibers 264 are angled relative to other fibers of the fibers 264. For example, at least some of the fibers 264 form a checkered pattern. In one embodiment, at least some of the fibers 264 extend along the length L of the strip 260. For example, less than 20% of the fibers 264, less than 10% of the fibers 264, or less than 5% of the fibers 264 extend along the length L of the strip 260. In alternative embodiments, the fibers 264 of the strip 260 may be oriented in any direction. When flax is used as a low-density filler, the orientation of the fibers may not be important. The fibers may not be oriented in the main direction of the strip. In another alternative embodiment, the fibers 264 may be aligned with a load path that is different from the orientation of the strip.

[0110] The strip 260 may have any number of shapes and / or sizes. For example, the shape of the strip 260 is rectangular. Other shapes such as, for example, square strips and non-rectangular parallelogram strips may be provided. The strip 260 may include a width W perpendicular to the length L. The length L may be defined by, for example, the size of the radially outer tire engaging portion 202, the first sidewall 206, the second sidewall 208, and / or the radially inner portion 204 of the composite rim 200. In other words, the length L may be at least as high or as wide as the radially outer tire engaging portion 202, the first sidewall 206, the second sidewall 208, and / or the radially inner portion 204 of the composite rim 200. In one embodiment, the width W of the strip 260 is between 10 mm and 50 mm. For example, the width W of the strip 260 is 30 mm. In other embodiments, the strip 260 is wider or narrower (e.g., 60 mm). In one embodiment, the width W of the strip 260 is as wide as the radial width of the composite rim 200 .

[0111] Different shapes, greater widths, and / or greater lengths of layers 260 may be used. For example, at least some of the layers 260 of the third composite material may extend a quarter, half, or all the way around the rim (e.g., forming a portion of the groove 218). Different sizes and / or shapes of the layers 260 of the third composite material may be used depending on the application within the rim (e.g., providing thickness and stiffness at high load locations within the composite rim 200).

[0112] The layer 260 of the third composite material can have any number of thicknesses. In one embodiment, the layer 260 includes a plurality of material plies and is thicker than the layer 250 of the first composite material. Each of the plurality of material plies of the layer 260 of the third composite material can be unidirectional and can be stacked and stitched together so as to form a checkered pattern or a hash mark pattern. In other words, at least some of the plurality of material plies of the layer 260 of the third composite material are unidirectional in different directions, respectively. For example, the thickness of the layer 260 of the third composite material can be 1.2 mm or thicker. The layer 260 of the third composite material of other thicknesses can be provided.

[0113] Reference Figure 3 , Figure 4 and Figure 7 , the radially inner portion 204 of the composite rim 200 includes a plurality of openings 280 extending through the radially inner portion 204 of the composite rim 200. At least some of the plurality of openings 280 are, for example, spoke holes through which spokes (e.g., spoke 124) extend and at which the spokes are attached to the composite rim 200.

[0114] Any number of spoke holes 280 may be provided through the radially inner portion 204 of the composite rim 200. For example, the composite rim 200 may include 34 or 36 spoke holes 280 extending through the radially inner portion 204 of the composite rim 200. In other embodiments, the composite rim 200 includes more or fewer spoke holes 280. For example, the spoke holes 280 may have any number of shapes (e.g., circular) and sizes (e.g., sized based on the size of the spokes and / or spoke nipples that are to be attached to the composite rim 200 at the spoke holes 280).

[0115] The spoke holes 280 can be evenly distributed circumferentially around the radially inner portion 204 of the composite rim 200 such that the arc length between adjacent spoke holes 280 is the same for each pair of adjacent spoke holes 280. In one embodiment, the distribution of the spoke holes 280 varies around the radially inner portion 204 of the composite rim 200 (e.g., circumferentially or axially).

[0116] In one embodiment, all of the spoke holes 280 are centered within the radially inner portion 204 of the composite rim 200. In another embodiment, some or all of the spoke holes 280 are offset relative to the center of the radially inner portion 204 of the composite rim 200.

[0117] At least one first layer 282 of the second composite material forms at least a portion of the radially inner portion 204 of the composite rim 200 such that the second composite material (e.g., not the first composite material or the third composite material) surrounds each of the plurality of openings 280. Figures 3 to 7In the embodiment shown in FIG. 2 , the at least one first layer 282 of the second composite material extends circumferentially such that the at least one first layer 282 of the second composite material forms at least a portion of the radially inner portion 204 around the entirety of the composite rim 200 .

[0118] The at least one first layer 282 of the second composite material can have any number of shapes and / or sizes. For example, the at least one first layer 282 of the second composite material can be rectangular in shape and can extend around the entirety of the inner circumference of the composite rim 200. As such, the length of the at least one first layer 282 of the second composite material can correspond to the inner circumference of the composite rim 200, and the width of the at least one first layer 282 of the second composite material can correspond to the width of the radially inner portion 204 of the composite rim 200. The thickness of the at least one first layer 282 of the second composite material can be uniform, or can vary across the length and / or width of the at least one first layer 282 of the second composite material. Other shapes and / or sizes can be provided.

[0119] In other embodiments, the radially inner portion 204 of the composite rim 200 includes additional openings. For example, the composite rim 200 includes a valve opening and / or one or more openings in which one or more electronic components for a bicycle (e.g., bicycle 50) can be supported. The at least one first layer 282 of the second composite material can also surround such openings through the radially inner portion 204 of the composite rim 200.

[0120] like Figures 3 to 7 , at least two layers 284a, 284b of the first composite material may respectively form at least a portion of the first sidewall 206 and the second sidewall 208. The at least two layers 284a, 284b of the first composite material may also form a portion of the radially outer tire engaging portion 202. For example, the first layer 284a of the first composite material may at least partially form the first tire retaining portion 210 (e.g., the first tire retaining wall 214), and the second layer 284b of the first composite material may at least partially form the second tire retaining portion 212 (e.g., the second tire retaining wall 216).

[0121] Each of the at least two layers 284a, 284b of the first composite material can have any number of shapes and / or sizes. For example, the shape of each of the at least two layers 284a, 284b of the first composite material can be annular and can extend around the entirety of the composite rim 200. As such, the width of the respective layers 284a, 284b of the first composite material can correspond to the height of the first sidewall 206 or the second sidewall 208. In one embodiment, the width of the respective layers 284a, 284b of the first composite material can correspond to the height of the first tire retaining wall 214 or the second tire retaining wall 216 plus the height of the first sidewall 206 or the second sidewall 208, respectively. The thickness of each of the at least two layers 284a, 284b of the first composite material can be uniform, or can vary around and / or across the width of the respective layers 284a, 284b of the first composite material. Other shapes and / or sizes can be provided.

[0122] Reference Figure 3 , Figure 4 and Figure 7 , the radially outer tire engaging portion 202 of the composite rim 200 includes a plurality of openings 290 extending through the radially outer tire engaging portion 202 of the composite rim 200. At least some of the plurality of openings 290 are, for example, access holes through which spokes (e.g., spoke 124) can be accessed (e.g., tightened and loosened). The spokes can be accessed via the access holes 290 using, for example, a tool.

[0123] Any number of access holes 290 may be disposed through the radially outer tire engaging portion 202 of the composite rim 200. The number of access holes 290 may correspond to the number of spoke holes 280. For example, the composite rim 200 may include 34 or 36 access holes 290 extending through the radially outer tire engaging portion 202 of the composite rim 200. In other embodiments, the composite rim 200 includes more or fewer access holes 290. For example, the access holes 290 may have any number of shapes (e.g., circular) and sizes (e.g., sized based on the size of a tool that may be used to tighten or loosen the spokes).

[0124] The access holes 290 can be evenly distributed circumferentially around the radially outer tire engaging portion 202 of the composite rim 200 such that the arc length between adjacent access holes 290 is the same for each pair of adjacent access holes 290. In one embodiment, the distribution of the access holes 290 varies (e.g., circumferentially or axially) around the radially outer tire engaging portion 202 of the composite rim 200 (e.g., corresponding to a varying distribution of the spoke holes 280).

[0125] In one embodiment, all of the access holes 290 are centered within the radially outer tire engaging portion 202 of the composite rim 200. For example, all of the access holes 290 are located within the groove 218 of the radially outer tire engaging portion 202 of the composite rim 200 (e.g., partially within the groove 218 and partially within the first shelf 220 and the second shelf 222). In another embodiment, some or all of the access holes 290 are offset relative to the center of the radially outer tire engaging portion 202 of the composite rim 200.

[0126] Reference Figure 3 , Figure 4 , Figure 6 and Figure 7 , at least one second layer 292 of the second composite material forms at least a portion of the radially outer tire engaging portion 202 of the composite rim 200 such that the second composite material (e.g., not the first composite material or the third composite material) surrounds each of the plurality of openings 290. Figures 3 to 7 In the embodiment shown in FIG. 2 , the at least one second layer 292 of the second composite material extends circumferentially such that the at least one second layer 292 of the second composite material forms at least a portion of the radially outer tire engaging portion 202 around the entirety of the composite rim 200 .

[0127] The at least one second layer 292 of the second composite material can have any number of shapes and / or sizes. For example, the shape of the at least one second layer 292 of the second composite material can be rectangular before the composite laminate is cured, and can be u-shaped after the composite laminate is cured. The second layer 292 of the second composite material can extend around the entirety of the outer circumference of the composite rim 200. As such, the length of the at least one second layer 292 of the second composite material can correspond to the outer circumference of the composite rim 200, and the width of the at least one second layer 292 of the second composite material can correspond to the width of at least a portion of the radially outer tire engaging portion 202 (e.g., the groove 218, the first shelf 220, and the second shelf 222) of the composite rim 200. The thickness of the at least one second layer 292 of the second composite material can be uniform, or can vary across the length and / or width of the at least one second layer 292 of the second composite material. Other shapes and / or sizes can be provided.

[0128] In other embodiments, the radially outer tire engaging portion 202 of the composite rim 200 includes additional openings. The at least one second layer 292 of the second composite material may also surround such openings through the radially outer tire engaging portion 202 of the composite rim 200.

[0129] In the layup pattern before curing, for example, at least one first layer 282 of the second composite material may abut at least two layers 284a, 284b of the first composite material, and at least one second layer 292 of the second composite material may abut at least two layers 284a, 284b of the first composite material, so that after curing, for example, a one-piece integral rim 200 is formed. In one embodiment, before curing, portions on opposite sides of at least one first layer 282 of the second composite material may overlap with at least two layers 284a, 284b of the first composite material, respectively, and portions on opposite sides of at least one second layer 292 of the second composite material may overlap with at least two layers 284a, 284b of the first composite material, respectively.

[0130] In one embodiment, one or more layers of a third composite material may be included within the composite laminate of composite rim 200 to provide thickness and stiffness at a lower cost than using only layers of the first composite material. In one embodiment, the layers of the third composite material may not form any outer surface of composite rim 200 (e.g., except for the outermost portions of first tire retaining wall 214 and second tire retaining wall 216, respectively). For example, a first layer of the third composite material partially forms first sidewall 206 and is adjacent to first layer 284a of the first composite material, and a second layer of the third composite material partially forms second sidewall 208 and is adjacent to second layer 284b of the first composite material.

[0131] Surrounding the holes (e.g., spoke holes 280 and access holes 290) through the composite rim 200 with a second composite material (e.g., a carbon fiber composite material) reduces or prevents moisture degradation of the composite rim 200 at the holes. The second composite material (e.g., a carbon fiber composite material) is an inherently solid and non-hygroscopic material.

[0132] Other configurations may be provided. For example, the composite laminates of the composite rim 200 may include more, fewer, and / or different composite materials. As another example, the composite laminates of the composite rim 200 may include more, fewer, and / or different layers. For example, the composite laminates of the composite rim 200 for the front wheel 54 may be the same as the composite laminates of the composite rim 200 for the rear wheel 56. Alternatively, for example, the composite laminates of the composite rim 200 for the front wheel 54 and the rear wheel 56 may be different.

[0133] Figures 3 to 7 Each layer (e.g., the first layer, the second layer, etc.) of the composite material (e.g., the first composite material, the second composite material, the third composite material, etc.) of the previous embodiment shown in FIG. 1 may be composed of a plurality of strip plies. The strip plies of each composite layer are connected. For example, the strip plies of each composite layer may be connected in an overlapping pattern or a staggered pattern to form Figure 3 The composite rim 200 shown in FIG. Other patterns known to those skilled in the art may be used to form the composite rim 200.

[0134] Figure 17 to Figure 18 Depicted is the construction of a rim 600 using an overlapping pattern. For example, Figures 3 to 7 The rim 200 in the embodiment of can be constructed using this overlapping pattern. Specifically, the first layer 604 of the second composite material can be attached to the first layer 607 of the first composite material at the overlapping joint 1000. The first layer 604 of the second composite material can be attached to the second layer 608 of the first composite material at the overlapping joint 1100. The second layer 602 of the second composite material can be attached to the first layer 607 of the first composite material at the overlapping joint 1010. The second layer 602 of the second composite material can be attached to the second layer 608 of the first composite material at the overlapping joint 1110.

[0135] The first layer 604 of the second composite material forms at least a portion of the radially inner portion 204 of the composite rim 600. The first layer 604 of the second composite material surrounds each of the plurality of openings 280. The first layer 604 of the second composite material is composed of three strip plies. The strip plies include a first ply 604a, a second ply 604b, and a third ply 604c. The first ply 604a is the innermost ply. The first ply 604a is further away from the outer side surface of the rim 600 than the second ply 604b and the third ply 604c. The third ply 604c is the outermost ply. The third ply 604c forms at least a portion of the outer surface of the rim 600. The second ply 604b is located between the first ply 604a and the third ply 604c.

[0136] In an example implementation, if Figure 17 to Figure 18 As shown in , the two layers 607, 608 of the first composite material can form at least a portion of the first sidewall 206 and the second sidewall 208, respectively. The two layers 607, 608 of the first composite material can also form a portion of the radially outer tire engaging portion 202. For example, the first layer 607 of the first composite material can at least partially form the first tire retaining portion 210 (e.g., the first tire retaining wall 214). The second layer 608 of the first composite material can at least partially form the second tire retaining portion 212 (e.g., the second tire retaining wall 216).

[0137] exist Figure 17 to Figure 18In the example embodiment shown in FIG. 6 , the first layer 607 is composed of three strip plies. The strip plies include a first ply 607a, a second ply 607b, and a third ply 607c. The first ply 607a is the innermost ply. The first ply 607a is further away from the outside of the rim 600 than the second ply 607b and the third ply 607c. The third ply 607c is the outermost ply. The third ply 607c forms at least a portion of the outer surface of the rim 600. The second ply 607b is located between the first ply 607a and the third ply 607c.

[0138] The second layer 608 is composed of three strip plies. These strip plies include a first ply 608a, a second ply 608b, and a third ply 608c. The first ply 608a is the innermost ply. The first ply 608a is farther away from the outside of the rim 600 than the second ply 608b and the third ply 608c. The third ply 608c is the outermost ply. The third ply 608c forms at least a portion of the outer surface of the rim 600. The second ply 608b is located between the first ply 608a and the third ply 608c.

[0139] exist Figure 17 to Figure 18 In the example embodiment shown in FIG. 1 , the second layer 602 of the second composite material forms at least a portion of the radially outer tire engaging portion 202 of the composite rim 600. The second layer 602 of the second composite material surrounds each of the plurality of openings 290. The second layer 602 of the second composite material includes three strip plies. The three strip plies are composed of a first ply 602a, a second ply 602b, and a third ply 602c. The first ply 602a is the innermost ply. The first ply 602a is further away from the outer side surface of the rim 600 than the second ply 602b and the third ply 602c. The third ply 602c is the outermost ply. The third ply 602c forms at least a portion of the outer surface of the rim 600. The second ply 602b is located between the first ply 602a and the third ply 602c.

[0140] Figure 17 to Figure 18The example embodiment shown in the figure depicts an overlapping configuration of composite material plies. In general, the rim 600 includes four overlapping joints 1000, 1100, 1010, 1110 extending circumferentially around the rim. The joints 1000, 1100, 1010, 1110 are formed by the interconnection of two different materials. In the overlapping configuration, the joint forms a stepped configuration. The two materials are inversely proportional in the stepped configuration. For example, when the first layer stretches, the second layer retreats in a stepped configuration, and vice versa. This can be done by the configuration shown in the embodiment. In addition, the first ply 604a is longer than the second ply 604b. The second ply 604b is longer than the third ply 604c. The two first plies 607a, 608a are shorter than the two second plies 607b, 608b. The two second plies 607b, 608b are shorter than the two third plies 607c, 608c. The first layer 602a is longer than the second layer 602b. The second layer 602b is longer than the third layer 602c.

[0141] The first overlap joint 1000 is now described. Specifically, the left end of the first ply 604a extends to and is placed on the end of the first ply 607a. The left end of the second ply 604b extends to and is placed on the end of the second ply 607b. The left end of the second ply 604b is also aligned with the end of the first ply 607a. The left end of the third ply 604c is placed on and beside the third ply 607c. The left end of the third ply 604c is also aligned with the end of the second ply 607b.

[0142] Now describe the second overlap joint 1100. The right end of the first ply 604a extends over and is placed on the end of the first ply 608a. The right end of the second ply 604b extends over and is placed on the end of the second ply 608b. The right end of the second ply 604b is also aligned with the end of the first ply 608a. The right end of the third ply 604c is placed on and beside the third ply 608c. The right end of the third ply 604c is also aligned with the end of the second ply 608b.

[0143] For the joints 1000 and 1100, the first ply 604a is further away from the outside of the radially inner portion 204 of the rim 600 than the two first plies 607a, 608a. The first ply 604a is the innermost layer for the joints 1000, 1100. The end of the second ply 604b is further away from the outside of the radially inner portion 204 of the rim 600 than the ends of the two second plies 607b, 608b where they overlap. The second ply 604b and the two first plies 607a, 608a are equidistant from the outside of the rim 600 at the point where they meet. The third ply 604c is further away from the outside of the radially inner portion 204 of the rim 600 than the two third plies 607c, 608c where they overlap. The end of the third ply 604c and the ends of the two third plies 607c, 608c are equidistant from the outside of the rim 600 at the point where they meet. The end of the third ply 604c and the ends of the two third plies 607b, 608b are equidistant from the outside of the rim 600 at the point where they meet. All of the plies in the two first plies 607a, 608a are cut before the center of the opening 280 and / or the radially inner portion 204 of the rim 600. Therefore, the first layer 604 of the second composite material is the only layer around the center of the opening 280 and / or the radially inner portion 204 of the rim 600.

[0144] As in Fig.17 and Fig.18 As can be seen in FIG. 1 , when viewed from top to bottom, the plies 604a to 604b to 604c of the first layer 604 are receding from 604a to 604c in length. In this case, the top is the ply closest to the tire joint portion 202. Ply 604c has the shortest length. Therefore, in this example, the first layer 604 depicts a receding step-like configuration at the joints 1000 and 1100. On the contrary, the plies 607a, 607b, 607c, 608a, 608b and 608c of the first layer 607 and the second layer 608 of the first composite material extend from ply 607a to ply 607c and from ply 608a to ply 608c at the joints 1000 and 1100. Therefore, in this example, the first layer 607 and the second layer 608 have an extended step-like configuration.

[0145] The third overlapping joint 1010 is now described. Specifically, the left end of the first ply 602a extends below the end of the first ply 607a and is placed below the end. The left end of the second ply 602b extends below the end of the second ply 607b and is placed below the end. The left end of the second ply 602b is also aligned with the end of the first ply 607a. The left end of the third ply 602c is placed below and beside the end of the third ply 607c. The left end of the third ply 602c is also aligned with the end of the second ply 607b.

[0146] Now describe the fourth overlap joint 1110. The right end of the first ply 602a extends below the end of the first ply 608a and is placed below the end. The right end of the second ply 602b extends below the end of the second ply 608b and is placed below the end. The right end of the second ply 602b is also aligned with the end of the first ply 608a. The right end of the third ply 602c is placed below and beside the end of the third ply 608c. The right end of the third ply 602c is also aligned with the end of the second ply 608b.

[0147] For the joints 1010 and 1110, the first ply 602a is further from the outside of the radially outer tire engaging portion 202 of the rim 600 than the two first plies 607a, 608a where they overlap. The second ply 602b is further from the outside of the radially outer tire engaging portion 202 of the rim 600 than the two second plies 607b, 608b where they overlap. The second ply 602b and the two first plies 607a, 608a are equidistant from the outside of the rim 600 where they meet. The third ply 602c is further from the outside of the radially outer tire engaging portion 202 of the rim 600 than the two third plies 607c, 608c where they overlap. The end of the third ply 602c and the ends of the two third plies 607c, 608c are equidistant from the outside of the rim 600 where they meet. The third ply 602c and the two second plies 607b, 608b are equidistant from the outside of the rim 600 where they meet. The layers 607, 608 are cut toward the center of the opening 290 and / or the radially outer tire engaging portion 202 of the rim 600. Thus, the second layer 602 of the second composite material is the only layer surrounding the center of the opening 290 and / or the radially outer tire engaging portion 202 of the rim 600.

[0148] As in Fig.17 and Fig.18As can be seen in FIG. 1 , when viewed from top to bottom, the plies 602c, 602b, 602a of the second layer 602 are extended in length from ply 602c to ply 602a. In this case, the bottom is the ply closest to the radially inner portion 204. Ply 602c has the shortest length. Therefore, in this example, the second layer 602 depicts an extended stepped configuration at the joints 1010 and 1110. In contrast, the plies of the first layer 607 and the second layer 608 of the first composite material retreat at the joints 1000 and 1100. The plies 607a, 607b, 607c, 608a, 608b and 608c of the first layer 607 and the second layer 608 of the first composite material retreat from ply 607c to ply 607a and from ply 608c to ply 608a at the joints 1010 and 1110. The third plies 607c, 608c, the second plies 607b, 608b, and the first plies 607a, 608a decrease in length in a stepped manner at the junctions 1010 and 1110. Thus, in this example, the first ply 607 and the second ply 608 have a receding stepped configuration.

[0149] exist Figure 17 to Figure 18 In the embodiment shown in FIG. 6 , the first layer 604 of the second composite material extends circumferentially such that the first layer 604 of the second composite material forms at least a portion of the radially inner portion 204 around the entirety of the composite rim 600. In addition, the second layer 602 of the second composite material extends circumferentially such that the second layer 602 of the second composite material forms at least a portion of the radially outer tire engaging portion 202 around the entirety of the composite rim 600.

[0150] In alternative embodiments, more than one layer of the second composite material may be used, and each layer may be composed of more or less than three plies. In further alternative embodiments, more or less than two layers of the first composite material may be used, and each layer may be composed of more or less than three plies. In alternative embodiments, a third composite material may be used in place of the first composite material.

[0151] exist Fig.21 An example of an overlapping joint 800 can be seen in FIG. Fig.21, 802a, 802b, and 802c are the first, second, and third plies of the first composite material, respectively, and 801a, 801b, and 801c are the first, second, and third plies of the second composite material. Ply 801a of the second composite material extends a distance X3 above ply 802a of the first composite material. Distance X3 is the distance bounded by dashed lines 808 and 810. Ply 801b extends a distance X2 above ply 802b. Distance X2 is bounded by dashed lines 806 and 808. Ply 801b meets ply 802a at dashed line 808. Ply 801c extends a distance X1 above ply 802c. Distance X1 is bounded by dashed lines 804 and 806. Ply 801c meets ply 802b at dashed line 806. Distances X1, X2, and X3 are not the same. As disclosed in the figure, distance X3 is greater than distances X1 and X2. Distance X2 is the same as X1. In alternative embodiments, distances X1, X2 and X3 may be the same distance. In other alternative embodiments, distances X1, X2 and X3 may all be different distances. In the figure, first composite material 802 is shown as an elongated stepped configuration from ply 802a to ply 802c from top to bottom. On the contrary, second composite material is shown as having a retreated stepped configuration from ply 801a to ply 801c from top to bottom at joint 800. In alternative embodiments, more than one layer of each composite material may be used, and each layer may be composed of more than or less than three plies.

[0152] Figures 19 to 20 An embodiment of a rim 700 depicting a staggered pattern is shown. For example, Figures 3 to 7 The rim 200 in the embodiment of can be constructed using this staggered pattern. Specifically, the first layer 704 of the second composite material can be attached to the first layer 707 of the first composite material at the staggered joint 2000. The first layer 704 of the second composite material can be attached to the second layer 708 of the first composite material at the staggered joint 2100. The second layer 702 of the second composite material can be attached to the first layer 707 of the first composite material at the staggered joint 2010. The second layer 702 of the second composite material can be attached to the second layer 708 of the first composite material at the staggered joint 2110.

[0153] The first layer 704 of the second composite material forms at least a portion of the radially inner portion 204 of the composite rim 700. The first layer 704 of the second composite material surrounds each of the plurality of openings 280. The first layer 704 of the second composite material is composed of three strip plies. The three strip plies include a first ply 704a, a second ply 704b, and a third ply 704c. The first ply 704a is the innermost ply. The first ply 704a is further away from the outer side of the rim 700 than the second ply 704b and the third ply 704c. The third ply 704c is the outermost ply. The third ply 704c forms at least a portion of the outer surface of the rim 700. The second ply 704b is located between the first ply 704a and the third ply 704c.

[0154] In an example implementation, if Figures 19 to 20 As shown in , the two layers 707, 708 of the first composite material can form at least a portion of the first sidewall 206 and the second sidewall 208, respectively. The two layers 707, 708 of the first composite material can also form a portion of the radially outer tire engaging portion 202. For example, the first layer 707 of the first composite material can at least partially form the first tire retaining portion 210 (e.g., the first tire retaining wall 214). The second layer 708 of the first composite material can at least partially form the second tire retaining portion 212 (e.g., the second tire retaining wall 216).

[0155] The first layer 707 is composed of three strip plies. These strip plies include a first ply 707a, a second ply 707b, and a third ply 707c. The first ply 707a is the innermost ply. The first ply 707a is farther away from the outside of the rim 700 than the second ply 707b and the third ply 707c. The third ply 707c is the outermost ply. The third ply 707c forms at least a portion of the outer surface of the rim 700. The second ply 707b is located between the first ply 707a and the third ply 707c.

[0156] The second layer 708 is composed of three strip plies. These strip plies include a first ply 708a, a second ply 708b, and a third ply 708c. The first ply 708a is the innermost ply. The first ply 708a is farther away from the outside of the rim 700 than the second ply 708b and the third ply 708c. The third ply 708c is the outermost ply. The third ply 708c forms at least a portion of the outer surface of the rim 700. The second ply 708b is located between the first ply 708a and the third ply 708c.

[0157] In an example implementation, if Figures 19 to 20As shown, the second layer 702 of the second composite material forms at least a portion of the radially outer tire engaging portion 202 of the composite rim 700. The second layer 702 of the second composite material surrounds each of the plurality of openings 290. The second layer 702 of the second composite material is composed of three strip plies. The three strip plies include a first ply 702a, a second ply 702b, and a third ply 702c. The first ply 702a is the innermost ply. The first ply 702a is further away from the outer side surface of the rim 700 than the second ply 702b and the third ply 702c. The third ply 702c is the outermost ply. The third ply 702c forms at least a portion of the outer surface of the rim 700. The second ply 702b is located between the first ply 702a and the third ply 702c.

[0158] Figures 19 to 20 The example embodiment shown in the embodiment depicts a staggered configuration of composite material plies. Generally, the rim 700 includes four staggered joints 2000, 2100, 2010, 2110 extending circumferentially around the rim. The joints 2000, 2100, 2010, 2110 are formed of two different materials that are staggered. The configuration of the joints 2000, 2100, 2010, 2110 can be stepped. The joints 2000, 2100, 2010, 2110 depict the tapering of the first composite material. In addition, the joints 2000, 2100, 2010, 2110 depict the second composite material starting with an expanded or splayed configuration. In the expanded (splayed) configuration, the first composite material is thicker and sandwiched between the second composite materials, spacing the second composite materials apart. The spacing of the second composite material narrows as the first composite material tapers. This can be done by the configuration shown in the embodiment. In addition, the first ply 704a is longer than the second ply 704b. The second ply 704b is longer than the third ply 704c. The two first plies 707a, 708a are longer than the two second plies 707b, 708b. On the radially outer tire engaging portion 202 of the rim 700, the two second plies 707b, 708b are longer than the two third plies 707c, 708c, and on the radially inner portion 204 of the rim 700, the two second plies 707b, 708b are shorter than the two third plies 707c, 708c. The first ply 702a is shorter than the second ply 702b. The second ply 702b is shorter than the third ply 702c.

[0159] The first staggered joint 2000 is described herein. Specifically, the left end of the first ply 704a extends to the end of the first ply 707a and is placed on the end. The left end of the second ply 704b is located between the first ply 707a and the third ply 707c of the first composite material. In addition, the left end of the second ply 704b is aligned with the end of the second ply 707b. The left end of the second ply 704b extends to the end of the third ply 707c and is placed on the end. The left end of the third ply 704c extends below the end of the third ply 707c and is placed below the end.

[0160] The second staggered joint 2100 is described herein. The right end of the first ply 704a extends to the end of the first ply 708a and is placed on the end. The right end of the second ply 704b is located between the first ply 708a and the third ply 708c of the first composite material. The right end of the second ply 704b is aligned with the end of the second ply 708b. The right end of the second ply 704b extends to the end of the third ply 708c and is placed on the end. The right end of the third ply 704c extends below the end of the third ply 708c and is placed below the end.

[0161] For the joints 2000 and 2100, the first ply 704a is further away from the outside of the radially inner portion 204 of the rim 700 than the two first plies 707a, 708a where they overlap. The ends of the two first plies 707a, 708a are located between the ends of the first ply 704a and the ends of the second ply 704b. The ends of the two third plies 707c, 708c are located between the ends of the second ply 704b and the ends of the third ply 704c. The ends of the second ply 704b and the ends of the two second plies 707b, 708b are equidistant from the outside of the rim 700 where they meet. The second ply 704b is further away from the outside of the radially inner portion 204 of the rim 700 than the third plies 707c, 708c where they overlap. The third ply 704c is closer to the outside of the radially inner portion 204 of the rim 700 than the two third plies 707c, 708c where they overlap.

[0162] The plies (e.g., 707a, 707b, 707c, 708a, 708b, and 708c) of the first layer 707 and the second layer 708 of the first composite material taper off and decrease in thickness as they move toward the center of the opening 280 and / or the radially inner portion 204 of the rim 700. Thus, the first layer 704 of the second composite material is the only layer surrounding the center of the opening 280 and / or the radially inner portion 204 of the rim 700.

[0163] In this example, the ends of the plies 704a, 704b, and 704c of the first layer 704 of the second composite material are expanded or splayed. As the plies 704a, 704b, and 704c move toward the inner portion 204, the plies 704a, 704b, and 704c narrow inwardly. The narrowing rate can be related to the tapering rate of the first layer 707 and the second layer 708 of the first composite material and / or to the desired shape of the rim 700. The first layer 704 is most compressed at the center of the radially inner portion 204 in the absence of the first composite material.

[0164] The third overlapping joint 2010 is now described. The left end of the first ply 702a extends below the end of the first ply 707a and is placed below the end. The left end of the second ply 702b is located between the first ply 707a and the second ply 707b of the first composite material. The left end of the second ply 702b extends below the end of the second ply 707b and is placed below the end. The left end of the third ply 702c is located between the second ply 707b and the third ply 707c of the first composite material. The left end of the third ply 702c extends below the end of the third ply 707c and is placed below the end.

[0165] The fourth overlap joint 2110 is now described. The right end of the first ply 702a extends below the end of the first ply 708a and is placed below the end. The right end of the second ply 702b is located between the first ply 708a and the second ply 708b of the first composite material. The right end of the second ply 702b extends below the end of the second ply 708b and is placed below the end. The right end of the third ply 702c is located between the second ply 708b and the third ply 708c of the first composite material. The right end of the third ply 702c extends below the end of the third ply 708c and is placed below the end.

[0166] For the joints 2010 and 2110, the first ply 702a is further away from the outside of the radially outer tire engaging portion 202 of the rim 700 than the two first plies 707a, 708a where they overlap. The ends of the two first plies 707a, 708a are located between the ends of the first ply 702a and the ends of the second ply 702b. The ends of the two second plies 707b, 708b are located between the ends of the third ply 702c and the ends of the second ply 702b. The second ply 702b is further away from the outside of the radially outer tire engaging portion 202 of the rim 700 than the two second plies 707b, 708b where they overlap. The third ply 702c is further away from the outside of the radially outer tire engaging portion 202 of the rim 700 than the two third plies 707c, 708c where they overlap.

[0167] The plies (e.g., 707a, 707b, 707c, 708a, 708b, and 708c) of the first and second layers of the first composite material 707, 708 taper and decrease in thickness as they move toward the center of the radially outer tire engaging portion 202 of the opening 290 and / or rim 700. Thus, the second layer 702 of the second composite material is the only layer surrounding the center of the radially outer tire engaging portion 202 of the opening 290 and / or rim 700.

[0168] In this example, the ends of the plies 702a, 702b, and 702c of the second layer 702 of the second composite material are expanded or flared. As the plies 702a, 702b, and 702c move toward the center of the joint portion 202, the plies 702a, 702b, and 702c narrow inwardly. The narrowing rate can be related to the tapering rate of the first layer 707 and the second layer 708 of the first composite material and / or to the desired shape of the rim 700. The second layer 702 is most compressed at the center of the radial joint portion 202 in the absence of the first composite material.

[0169] exist Figures 19 to 20 In the embodiment shown in FIG. 7 , the first layer 704 of the second composite material extends circumferentially such that the first layer 704 of the second composite material forms at least a portion of the radially inner portion 204 around the entirety of the composite rim 700. In addition, the second layer 702 of the second composite material extends circumferentially such that the second layer 702 of the second composite material forms at least a portion of the radially outer tire engaging portion 202 around the entirety of the composite rim 700.

[0170] In alternative embodiments, more than one layer of the second composite material may be used, and each layer may be composed of more or less than three plies. In further alternative embodiments, more or less than two layers of the first composite material may be used, and each layer may be composed of more or less than three plies. In alternative embodiments, a third composite material may be used in place of the first composite material.

[0171] exist Fig. 22 An example of a staggered joint 900 can be seen in FIG. Fig. 22, respectively, 902a, 902b and 902c are the first ply, the second ply and the third ply of the first composite material, and 901a, 901b and 901c are the first ply, the second ply and the third ply of the second composite material. The ply 901a of the second composite material extends between the plies 902a and 902b of the first composite material. The ply 901a extends a distance Y3 below the ply 902a. The distance Y3 is defined by the dashed lines 910 and 908. The ply 901a extends onto the ply 902b of the second composite material and extends a distance Y2 plus Y3 (Y2+Y3) above the ply 902b. Y2 is defined by the dashed lines 906 and 908. Therefore, the total extension of the ply 901a on and / or above the ply 902b is between the dashed lines 906 and 910.

[0172] Ply 901b of the second composite material extends between plies 902b and 902c of the first composite material. Ply 901b extends below ply 902b by a distance Y2. Ply 901b extends onto ply 902c and extends above ply 902c by a distance Y1 plus Y2 (Y1+Y2). Distance Y1 is bounded by dashed lines 904 and 906. Thus, the total extension of ply 901b on and / or above ply 902c is bounded between dashed lines 904 and 908.

[0173] The ply 901c of the second composite material is positioned below the ply 902c at a distance Y1. In this embodiment, and as disclosed in the figures, the distances Y1, Y2 and Y3 are equal distances. In alternative embodiments, Y1, Y2 and Y3 are not equal distances.

[0174] Furthermore, in the illustrated embodiment, the first composite material 902 is shown as an elongated stepped configuration from top to bottom from ply 902a to ply 902c. Conversely, the second composite material 901 is shown as having a receding stepped configuration from top to bottom from ply 901a to ply 901c at the joint 900. In alternative embodiments, more than one layer of each composite material may be used, and each layer may be composed of more or less than three plies.

[0175] As an example of another configuration, Figures 10 to 14 A second embodiment of a composite rim 300 formed from layers of multiple composite materials is shown. The composite rim 300 also includes a plurality of openings 302 (e.g., spoke holes) extending through a radially inner portion 304 of the composite rim 300 and a plurality of openings 306 (e.g., access holes) extending through a radially outer tire engaging portion 308. A first sidewall 310 and a second sidewall 312 are spaced apart from each other and extend between the radially inner portion 304 and the radially outer tire engaging portion 308.

[0176] The spoke holes 302 and the inlet and outlet holes 306 are surrounded by the second composite material. Figures 3 to 7 In the first embodiment shown in FIG. 3 , the composite laminate of the composite rim 300 includes at least one first layer of a second composite material extending around the entirety of the composite rim 300 and forming at least a portion of the radially inner portion 304, the composite laminate of the composite rim 300 includes a plurality of first layers 314 of a second composite material at the plurality of openings 302 (e.g., spoke holes) and a plurality of second layers 316 of a second composite material at the plurality of openings 306 (e.g., inlet and outlet holes). In other words, the plurality of first layers 314 of the second composite material act as a first patch around the spoke holes 302 (e.g., no first composite material or third composite material surrounds the holes 302), and the plurality of second layers 316 of the second composite material act as a second patch around the inlet and outlet holes 306 (e.g., no first composite material or third composite material surrounds the inlet and outlet holes 306).

[0177] The first patch 314 can have any number of different shapes and / or sizes. For example, the first patch 314 can be square-shaped or rectangular (e.g., before curing). The width of the first patch 314 can correspond to the width of the radially inner portion 304 of the composite rim 300. In one embodiment, the width of the first patch 314 can be less than the width of the radially inner portion 304 of the composite rim 300. The length of the first patch 314 can be the same as, less than, or greater than the width of the first patch 314.

[0178] The second patch 316 can have any number of different shapes and / or sizes. For example, the second patch 316 can be square or rectangular in shape (e.g., before curing). The width of the second patch 316 can correspond to the width of a portion of the radially outer tire engaging portion 308 of the composite rim 300 (e.g., the groove 318 of the radially outer tire engaging portion 308, the first shelf 320 and the second shelf 322). In one embodiment, the width of the second patch 316 can be less than the width of a portion of the radially outer tire engaging portion 308 of the composite rim 300 (e.g., can correspond only to the width of the groove 318). The length of the second patch 316 can be the same as, less than, or greater than the width of the second patch 316.

[0179] In one embodiment, the remainder of the composite rim 300 is formed by at least one layer of the first composite material. For example, first layers 324 of the first composite material are respectively disposed between adjacent pairs of first patches 314 and form a portion (e.g., the remainder) of the radially inner portion 304 of the composite rim 300. Second layers 326 of the first composite material are respectively disposed between adjacent pairs of second patches 316 and form a portion (e.g., the remainder) of the radially outer tire engaging portion 308 of the composite rim 300. One or more third layers 328 of the first composite material form a first sidewall 310 extending between the radially inner portion 304 and the radially outer tire engaging portion 308 of the composite rim 300, and one or more fourth layers 330 of the first composite material form a second sidewall 312 extending between the radially inner portion 304 and the radially outer tire engaging portion 308 of the composite rim 300. The composite rim 300 may include more, fewer, and / or different layers, and / or may include more and / or different composite materials (e.g., a third composite material).

[0180] constitute Figures 10 to 14 The layers of the composite material of the embodiment shown in FIG. Figures 17 to 22 The plies of each layer can be arranged in an overlapping pattern (see Figure 17 to Figure 18 ) or staggered pattern (see Figures 19 to 20 ) configuration. Figures 17 to 22 The staggered or overlapping pattern is applied to Figures 10 to 14 In the embodiment shown in Figures 10 to 14 , these layers may not be as Figures 17 to 20 Rather than extending all around the rim as in the embodiment of the present invention, the patch may only be present locally where the patch is located. Other patterns known to those skilled in the art may be used to form the composite rim 300.

[0181] As yet another configuration example, Fig.15 A third embodiment of a composite rim 500 formed from layers of multiple composite materials is shown. Composite rim 500 again includes a plurality of openings 502 (e.g., spoke holes) extending through a radially inner portion 504 of composite rim 500 and a plurality of openings 506 (e.g., access holes) extending through a radially outer tire engaging portion 508. A first sidewall 510 and a second sidewall 512 are spaced apart from each other and extend between radially inner portion 504 and radially outer tire engaging portion 508.

[0182] Fig.15 The composite rim 500 of the third embodiment shown in FIG. Figures 10 to 143. For example, the composite laminate of the composite rim 500 includes a first patch 514 of a second composite material that forms a portion of a radially inner portion 504 of the composite rim 500 and a second patch 516 of a second composite material that forms a portion of a radially outer tire engaging portion 508 of the composite rim 500. The spoke holes 502 extend through the first patch 514, respectively, and the inlet and outlet holes 506 extend through the second patch 516, respectively.

[0183] The composite rim 500 also includes an opening 518 that forms a recess in which a device of the bicycle (e.g., an electronic device such as a sensor device) can be positioned and attached to the composite rim 500. The opening 518 can have any number of shapes and / or sizes. For example, the opening 518 can be shaped and sized to correspond to the shape and size of the electronic device to be disposed within the opening 518. The opening 518 can be larger than the spoke holes 502 and the access hole 506.

[0184] The composite laminate of the composite rim 500 also includes a third layer 520 (e.g., a third patch) of a second composite material, and the opening 518 extends through the third patch 520. The third patch 520 can be larger (e.g., have a larger width and / or length) than the first patch 514 and the second patch 516 to accommodate the larger opening 518. Forming (e.g., cutting) the opening 518 through the third patch 520 leaves a border 522 of the second composite material around the opening 518, so that the second composite material surrounds the opening 518. The border 522 of the second composite material can seal the opening 518 so that moisture degradation is reduced or prevented.

[0185] The composite material may need to be deburred or have unwanted resin removed from the molding process. This process may expose fibers (e.g., fibers of the first composite material). In one embodiment, an inherent sealing material (e.g., second composite material, fiberglass) may be used locally to seal the composite laminate at the opening 518 (e.g., to form a boundary 522).

[0186] constitute Fig.15 The layers of the composite material of the embodiment shown in FIG. Figures 17 to 22 The plies of each layer can be arranged in an overlapping pattern (see Figure 17 to Figure 18 ) or staggered pattern (see Figures 19 to 20 ) configuration. Figures 17 to 22 The staggered or overlapping pattern is applied to Fig.15 In the embodiment shown in Fig.15 , these layers may not be as Figures 17 to 20Rather than extending all around the rim as in the embodiment of the present invention, the patch may only be present locally where the patch is located. Other patterns known to those skilled in the art may be used to form the composite rim 500.

[0187] Fig.16 A method 1800 for manufacturing a bicycle component (e.g., rim 122) for a bicycle (e.g., bicycle 50) is shown. The actions of method 1800 presented below are intended to be illustrative. In some embodiments, method 1800 can be implemented with one or more additional actions not described and / or without one or more actions described. Additionally, in Fig.16 The order in which the actions in method 1800 are illustrated and described below is not intended to be limiting.

[0188] In action 1802, at least one layer (e.g., one layer) of a first composite material is positioned within a mold. The first composite material includes a matrix of a first polymer-based material and natural fibers of a first reinforcement material. In one embodiment, the fiber orientation of the natural fibers of the first reinforcement material of the layer of the first composite material is unidirectional in a direction along the length of the corresponding layer.

[0189] The layer of the first composite material can have any number of shapes and / or sizes. For example, the layer of the first composite material can be rectangular in shape and can have a width at least as large as the height of the sidewall of the rim to be manufactured. Other shapes and / or sizes can be provided.

[0190] The first polymer-based material can be or include any number of polymer-based materials, including, for example, thermoplastics, thermosetting matrices, or combinations thereof. The fibers of the first reinforcing material can be or include any number of different types of natural fibers, including, for example, flax fibers, kenaf fibers, hemp fibers, jute fibers, sisal fibers, or any combination thereof. Other polymer-based materials and / or other reinforcing materials can be used for the first composite material.

[0191] In one embodiment, the layer of the first composite material is positioned within the mold so that the layer of the first composite material forms at least a portion of one of the two sidewalls of the rim to be manufactured. In other embodiments, the layer of the first composite material is positioned within the mold so that the layer of the first composite material forms at least a portion of another portion of the rim to be manufactured (e.g., a radially inner portion of the rim to be manufactured).

[0192] In action 1804, at least one layer (e.g., one layer) of a second composite material is positioned in a mold so that the layer of the second composite material is adjacent to the layer of the first composite material. The second composite material includes a matrix of a second polymer-based material and fibers of a second reinforcing material. The second polymer-based material can be or include any number of polymer-based materials, including, for example, plastics, acrylic acid, resin, epoxy resin, or any combination thereof. The fibers of the second reinforcing material can be or include any number of different types of fibers, including, for example, carbon fibers. The second composite material can have a porosity lower than the first composite material. Other polymer-based materials and / or other reinforcing materials can be used for the second composite material.

[0193] The layer of the second composite material can have any number of shapes and / or sizes. For example, the layer of the second composite material can be rectangular in shape and can have a width at least as large as the width of the radially inner portion of the rim to be manufactured. Other shapes and / or sizes can be provided. In one embodiment, the layer of the second composite material is thicker than the layer of the first composite material. In another embodiment, the layer of the second composite material is thinner than the layer of the first composite material.

[0194] In one embodiment, the layer of the second composite material is positioned within the mold so that the layer of the second composite material forms at least a portion of a radially inner portion of the rim to be manufactured. In other embodiments, the layer of the second composite material is positioned within the mold so that the layer of the second composite material forms at least a portion of another portion of the rim to be manufactured (e.g., a radially outer tire engaging portion).

[0195] Actions 1802 and 1804 may be repeated any number of times to form a stacking pattern for a bicycle component. In one embodiment, actions 1802 and 1804 may be repeated with one or more additional actions, wherein one or more layers of other composite materials are positioned any number of times to form a stacking pattern, for example.

[0196] In one embodiment, action 1802 is repeated, and another layer of the first composite material is positioned in the mold so that the other layer of the first composite material forms at least a portion of the other of the two sidewalls of the rim to be manufactured. Action 1804 is also repeated, and another layer of the second composite material is positioned in the mold so that the other layer of the second composite material forms at least a portion of the radially outer tire engaging portion of the rim to be manufactured.

[0197] In another embodiment, action 1804 is repeated and another layer of the second composite material is positioned within the mold such that the other layer of the second composite material also abuts (e.g., overlaps) the layer of the first composite material. For example, the layer of the first composite material is disposed between the layer of the second composite material and another layer of the second composite material (e.g., the layer of the first composite material abuts the layer of the second composite material and another layer of the second composite material on opposite sides of the layer of the first composite material), and the layer of the first composite material, the layer of the second composite material, and another layer of the second composite material form a portion of the radially inner portion or the radially outer tire engaging portion of the rim to be manufactured. Actions 1802 and 1804 can be repeated, for example, around the inner circumference and / or outer circumference of the rim to be manufactured to form a rim that is, for example, radially inner or radially outer. Figures 10 to 14 The corresponding stacking pattern of the composite laminate shown in the second embodiment.

[0198] Once formed into a composite laminate, the layup pattern may correspond to Figures 3 to 7 A first embodiment of the invention Figures 10 to 14 The second embodiment of Fig.15 The composite laminate or another composite laminate shown in the third embodiment.

[0199] In act 1806, a bicycle component is formed. Forming the bicycle component includes forming a composite laminate (e.g., a laminate) including at least a layer of a first composite material and a layer of a second composite material within a mold. In one embodiment, forming the bicycle component includes forming a composite laminate including at least a layer of a first composite material, a layer of a second composite material, and a layer of a third composite material within a mold.

[0200] The mold may be used to form all or part of a bicycle component. For example, for a rim, the mold may be broken down into a plurality of parts to allow access to the mold when positioning at least a first layer of composite material in act 1802 and a second layer of composite material in act 1804. For example, the mold may be broken down into a plurality of circumferential portions (e.g., four circumferential portions) and / or a plurality of segments (e.g., a first sidewall segment, a second sidewall segment, and a radially outer segment).

[0201] Forming the composite laminate may include shaping and curing the composite laminate, for example, in a mold. For example, at least a layer of a first composite material and a layer of a second composite material may be positioned in a mold and shaped using a bladder that is expanded in the mold. The composite laminate may be shaped in other ways.

[0202] Once formed, the composite laminate may be cured in any number of ways including, for example, by press curing, autoclave curing, or oven curing the composite laminate comprising at least a first composite material layer and a second composite material layer. Other types of curing may be used.

[0203] In action 1808, an opening is formed through the layer of the second composite material of the composite laminate such that the second composite material surrounds the opening (e.g., without the first composite material surrounding the opening). The opening can be formed through the layer of the second composite material of the composite laminate in any number of ways, including, for example, drilling an opening through the layer of the second composite material. The opening through the layer of the second composite material can be formed in any number of other ways. For example, the opening through the layer of the second composite material can be formed by cutting an opening from the layer of the second composite material. The opening can be any number of different types of openings, including, for example, spoke holes, valve holes, access holes, recesses into which a device for a bicycle (e.g., an electronic device) can be positionable and attachable, or another type of opening.

[0204] Act 1808 may be repeated any number of times. For example, act 1808 may be repeated for another layer of the second composite material (e.g., as another valve hole or access hole) and any other layers of the second composite material through which openings (e.g., for spoke holes or access holes) are to extend.

[0205] In one embodiment in which the layer of the second composite material extends all of the composite laminate around the rim to form at least a portion of the radially inner portion of the rim or the radially outer tire engaging portion of the rim, action 1808 can be repeated any number of times (e.g., 34 or 36 times) such that a plurality of openings (e.g., spoke holes or access holes) are formed through the layer of the second composite material.

[0206] The plurality of openings may be formed through the layer of the second composite material in any number of configurations. For example, the plurality of openings may be formed through the layer of the second composite material such that the plurality of openings are evenly distributed around the rim (e.g., around a radially inner portion of the rim). Other configurations of the plurality of openings may be provided.

[0207] Any number of different bicycle components may be manufactured using the method 1800. For example, in addition to bicycle rims, the method 1800 may be used to manufacture crank arms, handlebars, stems, seat posts, seat tracks, shift levers, brake levers, derailleur cages, suspension fork components, and / or other bicycle components.

[0208] The illustrations of the embodiments described herein are intended to provide a general understanding of the structures of various embodiments. These illustrations are not intended to be used as a complete description of all elements and features of the equipment and systems utilizing the structures or methods described herein. Many other embodiments may be apparent to those skilled in the art after browsing this disclosure. Other embodiments may be utilized and may be inferred from this disclosure so that structural and logical replacements and changes may be made without departing from the scope of this disclosure. In addition, these illustrations are representative only and may not be drawn to scale. Certain ratios within the illustrations may be amplified, while other ratios may be minimized. Therefore, this disclosure and the accompanying drawings will be considered to be illustrative and not restrictive.

[0209] Although this specification contains many details, these should not be interpreted as limitations on the scope of the invention or the scope that can be claimed, but should be interpreted as descriptions of features specific to specific embodiments of the invention. Certain features described in this specification in the context of separate embodiments can also be implemented in a single embodiment in combination. Conversely, the various features described in the context of a single embodiment can also be implemented in multiple embodiments individually or in any suitable sub-combination. In addition, although features may be described above as working in certain combinations and even initially claimed as such, in some cases, one or more features in the claimed combination may be deleted from the combination, and the claimed combination may involve a sub-combination or a variation of the sub-combination.

[0210] Similarly, although operations and / or actions are depicted in the drawings and described herein in a particular order, this should not be understood as requiring that the operations be performed in the particular order shown or in a sequential order or that all illustrated operations be performed to achieve the desired results. In some cases, multitasking and parallel processing can be advantageous. In addition, the separation of various system components in the above-described embodiments should not be understood as requiring such separation in all embodiments, and it should be understood that any described program components and systems can be integrated together in a single software product or packaged into multiple software products as a whole.

[0211] The term "invention" is used herein only for convenience to refer to one or more embodiments of the present disclosure individually and / or collectively, and is not intended to actively limit the scope of the application to any particular invention or inventive concept. In addition, although specific embodiments have been illustrated and described herein, it should be understood that any subsequent arrangement designed to achieve the same or similar purpose may replace the specific embodiment shown. The present disclosure is intended to cover any and all subsequent modifications or variations of various embodiments. After reading the specification, the combination of the above embodiments and other embodiments not specifically described herein are obvious to those skilled in the art.

[0212] The Abstract of the present disclosure is provided to comply with 37 CFR §1.72(b) and is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims. In addition, in the above detailed description, various features may be grouped together or described in a single embodiment for the purpose of simplifying the disclosure. This disclosure is not to be interpreted as reflecting the intention that the claimed embodiments require more features than those expressly recited in each claim. Rather, as reflected in the appended claims, the inventive subject matter may be directed to less than all features of any one of the disclosed embodiments. Therefore, the following claims are incorporated into the detailed description, with each claim independently defining a separately claimed subject matter.

[0213] It is intended that the above specific embodiments be considered illustrative rather than restrictive, and it is understood that the following claims, including all equivalents, are intended to define the scope of the invention. The claims should not be construed as limited to the described order or elements unless otherwise stated. Therefore, all embodiments falling within the scope and spirit of the appended claims and their equivalents are claimed as inventions.

Claims

1. A rim for a bicycle wheel, the rim comprising: a radially inner portion, the radially inner portion being disposed along an inner circumference of the rim; a first side wall; a second sidewall spaced apart from the first sidewall, wherein the first and second sidewalls extend radially outward from the radially inner portion; and a radially outer tire engaging portion disposed along an outer circumference of the rim, the radially outer tire engaging portion extending from the first sidewall and the second sidewall, respectively; an opening extending through the radially inner portion, the first sidewall, the second sidewall, the radially outer tire engaging portion, or any combination thereof, wherein the first sidewall, the second sidewall, the radially outer tire engaging portion, the radially inner portion, or any combination thereof comprises a composite laminate including one or more compressed layers of a first composite material and one or more compressed layers of a second composite material, the second composite material being different from the first composite material and having a lower porosity than the first composite material, wherein the first composite material comprises a matrix of a polymer-based material and natural fibers for reinforcing the material, and wherein the opening extends through at least one of the one or more compressed layers of the second composite material such that the second composite material surrounds the opening.

2. The rim according to claim 1, wherein: The polymer-based material is a thermoplastic, a thermoset matrix, or a combination thereof, and Wherein, the natural fiber of the reinforcing material is flax fiber.

3. The rim according to claim 2, wherein: the polymer-based material is a first polymer-based material and the reinforcement material is a first reinforcement material, wherein the second composite material comprises a matrix of a second polymer-based material and fibers for a second reinforcing material, wherein the second polymer-based material is plastic, acrylic, resin, epoxy or any combination thereof, and Wherein, the fibers of the second reinforcing material are carbon fibers.

4. The rim according to claim 1, wherein: The opening is a first opening extending through the radially inner portion, wherein the rim further comprises a second opening extending through the radially outer tire engaging portion, wherein the at least one layer of the second composite material is at least one first layer of the second composite material, and wherein the second opening extends through at least one second layer of the one or more compressed layers of the second composite material such that the second composite material surrounds the second opening.

5. The rim according to claim 4, wherein: The first opening is a spoke hole, a valve hole, or an opening capable of supporting an electronic component of the bicycle, and Wherein, the second opening is an inlet and outlet hole.

6. The rim according to claim 4, wherein: The at least one first layer of the second composite material forms at least a portion of the radially inner portion, the portion of the radially inner portion extending around the entirety of the radially inner portion.

7. The rim according to claim 6, wherein: The at least one second layer of the second composite material forms at least a portion of the radially outer tire engaging portion, the portion of the radially outer tire engaging portion extending around the entirety of the radially outer tire engaging portion.

8. The rim according to claim 1, wherein: The opening is a first opening extending through the radially inner portion, and The rim further includes a second opening extending through the radially inner portion, wherein the second opening is spaced a certain distance from the first opening along the radially inner portion.

9. The rim according to claim 8, wherein: The at least one layer of the second composite material is at least one first layer of the second composite material, and wherein the second opening extends through at least one second layer of the one or more compressed layers of the second composite material such that the second composite material surrounds the second opening.

10. The rim according to claim 9, wherein: At least one of the one or more compressive layers of the first composite material partially forms the radially inner portion, the at least one layer of the first composite material being disposed between the at least one first layer of the second composite material and the at least one second layer of the second composite material.

11. The rim according to claim 8, wherein: The first opening and the second opening are spoke holes, respectively.

12. A method for manufacturing a bicycle component, the method comprising the steps of: positioning a layer of a first composite material within a mold, the first composite material comprising natural fibers of a first reinforcement material; positioning a layer of a second composite material within the mold so that a portion of the layer of the second composite material abuts, overlaps, or abuts and overlaps the layer of the first composite material, the second composite material comprising fibers of a second reinforcement material that is different from the first reinforcement material and has a lower porosity than the first composite material; forming the bicycle component, forming the bicycle component comprising forming a composite laminate including the layer of the first composite material and the layer of the second composite material within the mold; as well as An opening is formed through the layer of the second composite material of the composite laminate such that the second composite material surrounds the opening.

13. The method according to claim 12, wherein: The natural fibers of the first reinforcing material are flax fibers, and Wherein, the fibers of the second reinforcing material are carbon fibers.

14. The method according to claim 12, wherein: Forming the opening through the layer of the second composite material of the composite laminate includes drilling the opening through the layer of the second composite material of the composite laminate.

15. The method according to claim 12, wherein: The layer of the first composite material and the layer of the second composite material form a portion of a radially inner portion of the rim or a portion of a radially outer tire engaging portion of the rim, respectively.

16. The method according to claim 15, wherein: the layer of the second composite material is a first layer of the second composite material and the opening is a first opening, The method further comprises the following steps: positioning a second layer of the second composite material within the mold such that a portion of the second layer of the second composite material abuts, overlaps, or abuts and overlaps the layer of the first composite material and the layer of the first composite material is between the first layer of the second composite material and the second layer of the second composite material; and A second opening is formed through the composite laminate, forming the second opening includes forming the second opening through the second layer of the second composite material of the composite laminate such that the second composite material surrounds the second opening.

17. The method according to claim 12, wherein: The bicycle component is a rim, and wherein the layer of the second composite material extends all around the rim and forms at least a portion of a radially inner portion disposed along an inner circumference of the rim or at least a portion of a radially outer tire engaging portion disposed along an outer circumference of the rim.

18. The method according to claim 17, wherein: said layer of said second composite material being a first layer of said second composite material and forming at least a part of said radially inner portion of said rim, wherein the method further comprises positioning a second layer of the second composite material within the mold such that the layer of the first composite material is located between the first layer of the second composite material and the second layer of the second composite material, and wherein the second layer of the second composite material forms at least a portion of the radially outer tire engaging portion.

19. The method according to claim 18, wherein: The layer of the first composite material forms at least a portion of a sidewall of the rim.

20. A rim for a bicycle wheel, the rim comprising: a radially inner portion, the radially inner portion being disposed along an inner circumference of the rim; a first side wall; a second sidewall spaced apart from the first sidewall, wherein the first and second sidewalls extend radially outward from the radially inner portion; and a radially outer tire engaging portion disposed along an outer circumference of the rim, the radially outer tire engaging portion extending from the first sidewall and the second sidewall, respectively; a plurality of openings extending through the radially inner portion, the plurality of openings being spoke holes and spaced apart from one another about the radially inner portion, wherein at least the radially inner portion comprises a composite laminate comprising one or more compressed layers of a first composite material and one or more compressed layers of a second composite material, the second composite material being different from the first composite material and having a lower porosity than the first composite material, wherein the compression layer of the first composite material and the compression layer of the second composite material are each composed of strip plies of the corresponding composite material, wherein the first composite material comprises a matrix of a polymer-based material and natural fibers for reinforcing the material, and wherein the plurality of openings extend through at least one of the one or more compressed layers of the second composite material such that the second composite material surrounds the plurality of openings.

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