Manufacturing process of rim with spoke structure capable of being rapidly disassembled and assembled

Abstract

The invention provides a manufacturing process of a rim with a quick disassembly and assembly spoke structure, and belongs to the technical field of bicycle wheel manufacturing. The problems that a large number of spokes on an existing wheel are directly connected between a flange of a hub and a rim, air resistance is large, the weight is increased, and manufacturing complexity is increased are solved. The long-span spokes are adopted, local resin is burnt away through flames to enable carbon fibers to be exposed, the long spokes are composited at the exposed positions, carbon cloth is laid again during composite forming, each long spoke stretches across the rim, the two ends of each long spoke are anchored to the rim, the middle of each long spoke is connected with the hub, and the number of the spokes needed for achieving the same strength and rigidity can be remarkably reduced; the fewer spokes means lower air resistance and wind noise. By means of the scattering-reconstruction technology, connection between the spokes and the flanges is not simple surface bonding any more, but a fiber-interwoven microcosmic composite material interface is formed, and the connection strength is far higher than that of conventional bonding.

Description

Technical Field

[0001] This invention relates to the field of bicycle wheel manufacturing technology, and in particular to a manufacturing process for a wheel rim with a quick-release spoke structure. Background Technology

[0002] Modern high-performance bicycles, especially racing bicycles, generally prioritize lightweight, high-rigidity, and low-aerodynamic-resistance wheels. Carbon fiber composites, due to their excellent specific strength and specific modulus, have become the preferred material for manufacturing high-end wheels.

[0003] Traditional bicycle wheels, regardless of whether they use metal or carbon fiber spokes, have maintained a fundamentally unchanged basic structure for decades: dozens of independent spokes, each directly connected to the hub flange and rim via a single path, radially or laterally. This "hub-spoke-rim" force transmission path is unidirectional and dispersed. This structure has inherent limitations: firstly, to achieve driving and braking performance, a large number of spokes are needed to ensure strength and rigidity, resulting in significant air resistance; secondly, the large number of spokes and complex lacing also increase weight and manufacturing complexity. Summary of the Invention

[0004] The main objective of this invention is to address the shortcomings of existing technologies by providing a manufacturing process for wheel rims with a quick-assembly and disassembly spoke structure. This process employs a segmented manufacturing method and achieves a high-strength, high-precision connection between the spokes and the flange through unique pretreatment and mold positioning technologies.

[0005] The objective of this invention can be achieved through the following technical solutions: A manufacturing process for a wheel rim with a quick-release spoke structure, characterized by comprising the following steps: S1. Multiple spokes are pre-prepared, and each spoke has connectors at both ends for connecting to the wheel rim; S2. The spokes include carbon fiber bundles and a resin support covering the carbon fiber bundles; the middle of the spokes has a connecting section for connection with the flange, the resin support of the connecting section is removed to expose the internal carbon fiber bundles, and the connecting section is made soft and flexible by heating. S3. Fix the connectors at both ends of the spoke to determine the final effective length of the spoke. At this time, the exposed carbon fiber bundle in the middle of the spoke can be bent to adapt to the curved shape of the flange. S4. Place the pre-prepared flange into the mold, and place the positioned and bent spokes on the flange so that the exposed carbon fiber bundles in the middle of the spokes are in full contact with the flange. S5. Apply resin adhesive to the surface of the connection area between the spokes and the flange, and lay carbon fiber prepreg layer by layer above and below this area. S6. Mold closing and hot pressing curing are performed to solidify the spokes, resin adhesive, carbon fiber prepreg and flange into a whole under high temperature and high pressure to form a spoke assembly. S7. Two sets of spoke assemblies are connected and fixed to the hub to form a hub assembly; S8. The hub assembly is connected and fixed to the wheel rim to form a wheel.

[0006] In the manufacturing process of a wheel rim with a quick-release spoke structure described above, the heating method in step S2 is flame treatment, and the temperature is controlled at 150℃±10℃.

[0007] In the manufacturing process of a wheel rim with a quick-release spoke structure described above, the mold in step S4 includes an upper mold and a lower mold, with the flange and spokes fixedly installed on the lower mold.

[0008] In the manufacturing process of a wheel rim with a quick-release spoke structure described above, the lower die is provided with a positioning cavity for accommodating a flange, the flange is fixedly embedded in the positioning cavity, and the lower die is also provided with a pressure cap, which is placed above the flange and detachably fixed to the lower die by fasteners, for pressing and fixing the flange in the positioning cavity.

[0009] In the manufacturing process of the wheel rim with a quick-release spoke structure described above, the lower mold is also provided with several mounting positions, and the mounting positions are provided with grooves. The number of grooves corresponds to the number of spokes. The spokes are fixedly embedded in the grooves. Each mounting position is provided with a pressure block. The pressure block is placed above the spokes and is detachably fixed to the lower mold by fasteners, and is used to press and fix the spokes in the groove.

[0010] In the manufacturing process of the wheel rim with a quick-release spoke structure described above, the pressure block is also provided with a slot, and the connector at the end of the spoke is locked in the slot to restrict the movement of the spoke.

[0011] In the manufacturing process of a wheel rim with a quick-release spoke structure described above, the lower die is further provided with several pressure plates. The pressure plates are located between the flange and the connector. The pressure plates are detachably fixed to the lower die by fasteners and are used to press and fix the spokes on the lower die.

[0012] In the manufacturing process of a wheel rim with a quick-release spoke structure described above, before step S1, the theoretical length of the spokes is calculated based on the wheel's design parameters, and a bending allowance is reserved during actual manufacturing. This allowance is used to compensate for the length loss caused by bending in step S2.

[0013] In the manufacturing process of the wheel rim with a quick-release spoke structure described above, the two spoke assemblies in step S7 have different numbers of spokes; one set of spoke assemblies has 6 spokes, and the other set has 3 spokes; the spoke assembly closer to the bicycle chain has 6 spokes, and the spoke assembly further away from the bicycle chain has 3 spokes. The side closer to the bicycle chain experiences more stress, while the side further away experiences less stress; therefore, 6 spokes are placed on the side closer to the bicycle chain, and 3 spokes are placed on the side further away from the bicycle chain.

[0014] In the manufacturing process of the wheel rim with a quick-release spoke structure described above, in step S7, the two sets of spoke assemblies are respectively screwed to the hub by nuts. Each end of the hub is provided with a flange, and the flange is sleeved on the flange. The nut is threaded onto the hub and located on the outside of the flange. The inner side of the nut abuts against the flange to press and fix the flange onto the hub.

[0015] In the manufacturing process of the aforementioned wheel rim with a quick-release spoke structure, the inner bore of the flange is non-circular, and the cross-sectional shape of the flange matches the inner bore shape. The spoke assembly and hub are fixed using a hexagonal plug-in connection, nut locking, and adhesive fixation. Compared to existing technologies that only use adhesive or screw fixation, the fixing method of this invention is more robust and screwless.

[0016] Compared with the prior art, the present invention has the following beneficial effects: 1. This invention completely overturns the traditional radial force transmission pattern of "hub-spoke-rim". Since each spoke spans the rim, with both ends anchored to the rim and the middle connected to the hub, the driving and braking forces from the hub are first transmitted to the middle of the spokes, then simultaneously and symmetrically transmitted to both ends of the spokes, and finally distributed to the two extensive contact surfaces of the rim. This force transmission path better conforms to the principle of triangular stability, greatly improving the driving and torsional rigidity of the wheel, resulting in a more direct and efficient power response.

[0017] 2. Traditional multi-spoke wheels generate significant turbulence. This invention, by employing "long-span" spokes, can significantly reduce the number of spokes required to achieve the same strength and rigidity. Fewer spokes mean lower air resistance and wind noise. Simultaneously, this structure provides more space to design the spokes into airfoil sections with optimal aerodynamic effects, thereby further reducing wind resistance.

[0018] 3. By burning off some of the resin with a flame to expose the carbon fibers, and then re-laying carbon cloth during composite molding, a completely new, cross-boundary fiber-reinforced structure is essentially constructed at the joint. This "disassembly-reconstruction" process means that the connection between the spokes and the flange is no longer a simple surface bonding, but rather forms a microscopic composite material interface with interwoven fibers, resulting in a connection strength far exceeding that of conventional bonding.

[0019] 4. By using positioning clamps at both ends of the mold to directly fix the metal parts at the ends of the spokes, the actual connection state of the spokes on the final wheel is simulated. This allows for precise control of the effective length and spatial angle of each spoke, ensuring the radial and lateral runout accuracy of the finished wheel, as well as excellent dynamic balance performance. Attached Figure Description

[0020] Figure 1 This is a schematic diagram of the spoke assembly of the present invention; Figure 2 This is a schematic diagram of the structure of the hub assembly of the present invention; Figure 3 This is an enlarged cross-sectional view of the hub assembly of the present invention; Figure 4 This is a schematic diagram of the structure of the mold of the present invention; Figure 5 This is a schematic diagram of the structure of the lower mold of the present invention; In the diagram, 1 is the spoke; 2 is the connector; 3 is the flange; 4 is the hub; 5 is the upper die; 6 is the lower die; 7 is the positioning cavity; 8 is the gland; 9 is the groove; 10 is the pressure block; 12 is the pressure plate; 13 is the nut; and 14 is the flange. Detailed Implementation

[0021] The technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of this application, and not all of the embodiments. Based on the embodiments of this application, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of this application.

[0022] The manufacturing process of a wheel rim with a quick-release spoke structure according to the present invention includes the following steps: 1. Spoke preparation and calculation First, based on the wheel's design parameters (including rim diameter, hub flange distance, spoke angle, etc.), the theoretical effective length of each spoke is calculated. In actual spoke manufacturing, the initial length should be slightly greater than this theoretical value to allow for bending allowance. This allowance compensates for potential length loss during subsequent bending and shaping of the spoke connection section, ensuring that the tension of the spokes meets design requirements after final assembly.

[0023] 2. Independent preparation of spokes A specified number of carbon fiber spokes 1 are pre-manufactured independently using conventional pultrusion or molding processes. Each spoke 1 consists of a carbon fiber bundle serving as the load-bearing component, and a resin support covering it for shaping and protection. During molding, both ends of the spoke 1 are encapsulated with metal connectors 2, preferably made of titanium alloy, for subsequent connection to the wheel rim.

[0024] 3. Pretreatment of spoke connection section The middle section of spoke 1 is designated as a connecting segment for connection with flange 3. This connecting segment undergoes localized heat treatment using a flame treatment method, with the temperature precisely controlled within the range of 150℃±10℃. This process aims to ablate and remove the external resin support of the connecting segment, fully exposing the internal carbon fiber bundles. After this treatment, the carbon fiber bundles of the connecting segment become soft and malleable, capable of being bent by hand without breaking.

[0025] 4. Mold preparation and initial fixing Preheat the molding die to a suitable temperature. For example... Figure 4 As shown, the mold mainly includes an upper mold 5 and a lower mold 6. The lower mold 6 is provided with a precisely machined positioning cavity 7, which is used to accommodate and position the pre-prepared carbon fiber flange 3. After the flange 3 is placed into the positioning cavity 7, the pressure cover 8 is covered, and the pressure cover 8 is detachably fastened to the lower mold 6 using fasteners, thereby pressing and fixing the flange 3 in the positioning cavity 7.

[0026] 5. Spoke positioning and bending shaping like Figure 5 As shown, several grooves 9 corresponding to the number of spokes are provided around the positioning cavity 7 on the lower die 6 as mounting positions. The pre-treated spokes 1 from step 3 are inserted into the grooves 9. Each groove 9 has an independent pressure block 10 above it, and the pressure block 10 has a slot that matches the shape of the connector 2. The pressure block 10 is lowered so that the connector 2 is inserted into the slot, and then the pressure block 10 is fixed to the lower die 6 with fasteners, thereby firmly restricting the position of the end of the spoke 1 and determining its final effective length. The pre-treated, exposed and soft carbon fiber connecting section in the middle of the spoke 1 is in a free state because it has softened. By manually bending it, it is made to fit completely against the preset contact surface of the lower flange 3. To ensure a stable fit, a pressure plate 12 is provided above the spoke 1, and the pressure plate 12 is connected to the lower die 6 with fasteners to press and fix the spoke 1.

[0027] 6. Composite molding A layer of epoxy resin adhesive is evenly applied to the contact area between the curved joints of all spokes 1 and the flange 3. Then, multiple layers of unidirectional carbon fiber prepreg are laid layer by layer, alternating between the top and bottom of this connection area. After completion, the upper mold 5 is closed, and a certain pressure and temperature are applied to the mold for hot-press curing. During this process, the joints of spokes 1, the resin adhesive, the carbon fiber prepreg, and the flange 3 are solidified under high temperature and pressure into a high-strength, integrated spoke assembly (such as...). Figure 1 (As shown).

[0028] 7. Assembly of the spoke assembly and hub In this process, a complete wheel requires two spoke assemblies. The number of spokes 1 in the two assemblies is asymmetrically designed: the spoke assembly, which is expected to be installed on the side closer to the bicycle chain (drive side), has 6 spokes 1 because it bears a greater driving torque; the other side (non-drive side) has 3 spokes 1. The two spoke assemblies are then installed at both ends of the hub 4 (e.g., Figure 2 (As shown). Each end of the hub 4 has a flange 14 with a non-circular (e.g., hexagonal) cross-section. The shape of the center hole of the flange 3 matches the cross-section of the flange 14, enabling anti-rotation during insertion. (As shown) Figure 3 As shown, after fitting flange 3 onto the flange 14 of hub 4, screw nut 13 onto the threaded end of hub 4. The inner side of nut 13 abuts against the outer end face of flange 3, and tightening nut 13 axially presses flange 3 against the shoulder of flange 14. To further enhance reliability, structural adhesive can be applied to the mating surfaces. This "hexagonal plug anti-rotation + nut axial locking + adhesive" method constitutes an extremely robust connection.

[0029] 8. Wheel assembly Finally, the assembled hub assembly is connected to the rim via the connectors 2 at both ends of the spokes 1 (such as threaded or straight-pull connections) and the tension is adjusted to form a complete wheel.

[0030] It should be understood that in the claims and description of this invention, all instances of "comprising..." should be understood as having an open meaning, that is, their meaning is equivalent to "containing at least...", and should not be understood as having a closed meaning, that is, their meaning should not be understood as "containing only...".

[0031] The specific embodiments described herein are merely illustrative examples of the spirit of the invention. Those skilled in the art to which this invention pertains may make various modifications or additions to the described specific embodiments or use similar methods to substitute them, without departing from the spirit of the invention.

Claims

1. A manufacturing process for a wheel rim with a quick-release spoke structure, characterized in that, Includes the following steps: S1. Multiple spokes (1) are prepared in advance, and each spoke (1) has a connector (2) at both ends for connecting the wheel rim. S2, the spoke (1) includes a carbon fiber bundle and a resin support covering the carbon fiber bundle; the middle part of the spoke (1) has a connecting section for connecting with the flange (3), the resin support of the connecting section is removed to expose the internal carbon fiber bundle, and the connecting section is made soft and flexible by heating. S3. Fix the connectors (2) at both ends of the spoke (1) to determine the final effective length of the spoke (1). At this time, the exposed carbon fiber bundle in the middle of the spoke (1) can be bent to adapt to the curved shape of the flange (3). S4. Place the pre-prepared flange (3) into the mold, and place the positioned and bent spokes (1) on the flange (3) so that the exposed carbon fiber bundles in the middle of the spokes (1) are in full contact with the flange (3). S5. Apply resin adhesive to the surface of the connection area between the spoke (1) and the flange (3), and lay carbon fiber prepreg layer by layer above and below the area. S6. Close the mold and perform hot pressing and curing to solidify the spokes (1), resin adhesive, carbon fiber prepreg and flange (3) into a whole to form a spoke assembly; S7. The two sets of spoke assemblies are connected and fixed to the hub (4) to form a hub assembly; S8. The hub assembly is connected and fixed to the wheel rim to form a wheel.

2. The manufacturing process of a wheel rim with a quick-release spoke structure according to claim 1, characterized in that, The heating method in step S2 is flame treatment, and the temperature is controlled at 150℃±10℃.

3. The manufacturing process of a wheel rim with a quick-release spoke structure according to claim 1, characterized in that, The mold described in step S4 includes an upper mold (5) and a lower mold (6), with a flange (3) and spokes (1) fixedly installed on the lower mold (6).

4. The manufacturing process of a wheel rim with a quick-release spoke structure according to claim 3, characterized in that, The lower mold (6) is provided with a positioning cavity (7) for accommodating the flange (3). The flange (3) is fixedly embedded in the positioning cavity (7). The lower mold (6) is also provided with a pressure cap (8). The pressure cap (8) is placed above the flange (3) and is detachably fixed to the lower mold (6) by fasteners, for pressing and fixing the flange (3) in the positioning cavity (7).

5. The manufacturing process of a wheel rim with a quick-release spoke structure according to claim 3, characterized in that, The lower die (6) is also provided with several mounting positions, and grooves (9) are provided on the mounting positions. The number of grooves (9) corresponds to the number of spokes (1). The spokes (1) are fixedly embedded in the grooves (9). Each mounting position is provided with a pressure block (10). The pressure block (10) is placed above the spokes (1) and is detachably fixed to the lower die (6) by fasteners, and is used to press and fix the spokes (1) in the grooves (9).

6. The manufacturing process of a wheel rim with a quick-release spoke structure according to claim 5, characterized in that, The pressure block (10) is also provided with a slot, and the connector (2) at the end of the spoke (1) is locked in the slot to restrict the movement of the spoke (1).

7. The manufacturing process of a wheel rim with a quick-release spoke structure according to claim 3, characterized in that, The lower mold (6) is also provided with several pressure plates (12). The pressure plates (12) are located in the middle of the spokes (1) and are detachably fixed to the lower mold (6) by fasteners, and are used to press and fix the spokes (1) on the lower mold (6).

8. The manufacturing process of a wheel rim with a quick-release spoke structure according to claim 1, characterized in that, Before step S1, the theoretical length of the spokes (1) is calculated based on the design parameters of the wheel, and a bending allowance is reserved during actual production. This allowance is used to compensate for the length loss caused by bending in step S2.

9. The manufacturing process of a wheel rim with a quick-release spoke structure according to claim 1, characterized in that, The two spoke assemblies in step S7 have different numbers of spokes (1); one spoke assembly has 6 spokes (1) and the other spoke assembly has 3 spokes (1); the spoke assembly closer to the bicycle chain has 6 spokes (1) and the spoke assembly further away from the bicycle chain has 3 spokes (1).

10. A manufacturing process for a wheel rim with a quick-release spoke structure according to claim 1 or 9, characterized in that, In step S7, the two sets of spoke assemblies are screwed and fixed to the hub (4) by nuts (13) respectively. The hub (4) has a flange (14) at both ends. The flange (3) is fitted on the flange (14). The nut (13) is threaded on the hub (4) and located on the outside of the flange (14). The inner side of the nut (13) abuts against the flange (3) to press and fix the flange (3) on the hub (4). The inner hole of the flange (3) is non-circular, and the cross-sectional shape of the flange (14) is adapted to the inner hole shape of the flange (3).

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