AERODYNAMIC OPTIMIZED BICYCLE WHEEL

Abstract

A rim for a bicycle wheel includes a radially inner portion disposed along an inner periphery of the rim, a first sidewall, and a second sidewall spaced 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 periphery of the rim. The radially outer tire-engaging portion extends from the first sidewall and the second sidewall, respectively. A maximum width of the rim is between 30 mm and 70 mm, and the rim has an aspect ratio of greater than 1.25 but less than 3.0.

Description

background

[0001] This application claims priority to U.S. Provisional Patent Application No. 63 / 618,594, filed January 8, 2024, the contents of which are hereby incorporated by reference in their entirety. 1. Area of Revelation

[0002] The present disclosure relates generally to a bicycle wheel and, more particularly, to an aerodynamically optimized bicycle wheel. 2. Description of the state of the art

[0003] Cyclists riding on road or gravel can use wide-tread tires (e.g., more than 34 mm wide) to improve overall vehicle efficiency on uneven and rough surfaces. These cyclists can ride at speeds where air resistance becomes a significant braking force (e.g., more than 15 mph).

[0004] Conventional aerodynamic bicycle wheels use outer rim widths between 25-35 mm, with a rim chord length significantly larger than the maximum outer width. The purpose of this large aspect ratio is to allow the airflow split by the leading edge of the wheel to return as much pressure as possible to downstream surfaces, thus helping to balance low pressure at the rear edge of the wheel and high pressures near a stagnation point at the leading edge. This reduces the wheel's overall aerodynamic drag. 3. general summary

[0005] An exemplary rim for a bicycle wheel. The rim includes a radially inner portion disposed along an inner periphery of the rim, a first sidewall, and a second sidewall spaced from the first sidewall. The first sidewall and the second sidewall extend radially outward from the radially inner portion. A radially outer tire-engaging portion is disposed along an outer periphery of the rim. The radially outer tire-engaging portion extends from the first sidewall and the second sidewall, respectively. A maximum width of the rim is between 30 mm and 70 mm, and the rim has an aspect ratio of greater than 1.25 but less than 3.0.

[0006] Example of a bicycle wheel for a bicycle. The wheel includes a rim having a radially inner portion disposed along an inner periphery of the rim, a first sidewall, and a second sidewall spaced from the first sidewall. The first sidewall and the second sidewall extend radially outward from the radially inner portion. A radially outer tire-engaging portion is disposed along an outer periphery of the rim. The radially outer tire-engaging portion extends from the first sidewall and the second sidewall, respectively. A tire having an inflated width greater than 34 mm is attachable to the rim such that a width of the tire is less than or equal to a maximum width of the rim when the tire is attached to the rim. The maximum width of the rim is between 30 mm and 70 mm, and the rim has an aspect ratio greater than 1.25 but less than 3.0. Short description of the drawings

[0007] Objects, features and advantages of the present invention will become apparent upon reading the following description in conjunction with the figures: Fig. Figure 1 is a schematic side view of a bicycle that may be constructed to use an aerodynamically optimized wheel; Fig. 2 is a side view of a wheel for a bicycle such as the bicycle of Fig. 1; Fig. Figure 3 is a perspective view of an embodiment of a rim of a wheel such as the wheel of Fig. 2; Fig. 4 shows a cross section of the rim of Fig. 3; Fig. 5 shows a profile of a cross section of the rim of Fig. 3, to which a tire is attached; Fig. Figure 6 shows a profile of a cross-section of another rim of a wheel, e.g., the wheel of Fig. 2, to which a tire is attached; and Fig. 7 is a flowchart of one embodiment of a method for manufacturing a rim. Detailed description of the revelation

[0008] One of the biggest improvements in wide-tire bicycles is the use of an airfoil-shaped rim, which both complements the tire width and has a sufficiently large aspect ratio to recapture the airflow split by the front edge of the wheel, thus minimizing low pressure on the rear surfaces of the wheel.

[0009] The Reynolds number of a moving fluid partially dictates the minimum airfoil aspect ratios effective for maintaining the attached flow. Bicycles operate in flow conditions with a Reynolds number that allows rim aspect ratios as low as 1.25 to provide significant aerodynamic benefits to a bicycle. Increasing the aspect ratio increases aerodynamic performance but is associated with higher manufacturing costs and increased weight for a given outer width.

[0010] Rim aspect ratios above 3.0 provide only minor aerodynamic improvements while significantly increasing manufacturing costs and rim weight. A large tire (e.g., wider than 34 mm) mounted on a conventional-width rim loses most of its aerodynamic benefit, as the combined shape of the wider tire and narrower rim is nowhere near an airfoil cross-section and causes airflow separation during use. This significantly increases drag, which has a serious impact on the energy required by the rider to maintain a given speed.

[0011] Larger tire sizes are typically combined with relatively narrow rim wells, as is standard industry practice and required by the European Tire and Rim Technical Organization (ETRTO). These same rims can be designed with a low-profile rim aspect ratio to prioritize low system weight over good aerodynamic performance. Tire well widths that combine well with a large tire are generally undesirable, as this combination requires a compromise in additional system weight. Furthermore, this combination would violate established ETRTO conventions.

[0012] Advances in manufacturing techniques and product development have made it possible to produce wide tire bed widths that are aerodynamically compatible with wide-base tires, but without the undesirable weight penalty compared to narrow tire bed widths. Furthermore, advances in testing have shown that aerodynamic performance can take precedence over weight savings in most applications when high average speeds are the desired effect.

[0013] The present disclosure provides examples of rims and wheels that address or mitigate one or more of the above-discussed and / or other disadvantages of wheels with a large tire (e.g., over 34 mm wide) on a conventional width rim (e.g., 25-35 mm). For example, the disclosed rims have a widest point that is between 36 and 70 mm at a radial distance distal to the midchord of a rim cross-section and an aspect ratio of greater than 1.25 but less than 3.0. The disclosed rims provide an aerodynamic advantage because the combined shape of the wide tire on the wider rim approximates an airfoil cross-section. The disclosed rims complement the tire width and have a sufficiently large aspect ratio to recapture the airflow split by the leading edge of the wheel, thus minimizing low pressure on the rear surfaces of the wheel.This reduces air resistance compared to wheels where a large tire is mounted on a rim of standard width.

[0014] About the drawings: Fig. 1 generally shows a bicycle 50 having wheels 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, each rotatably mounted to the frame 52, and a drivetrain 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 generally further includes a seat 64 near a rear end of the frame 52 and is supported by one end of a seat post 66 connected to the frame 52. The bicycle 50 further includes handlebars 68 near a front end of the frame 52. The handlebar 68 carries a brake lever 70 for actuating the front brake 60, the rear brake 62 or the front brake 60 and the rear brake 62.If the brake lever 70 actuates only the front brake 60 or the rear brake 62, a second brake lever (not shown) may be provided to actuate the other brake. A frontward and / or forward direction of travel or orientation of the bicycle 50 is indicated by the direction of arrow A in . Fig. 1. A forward direction for the bicycle 50 is therefore indicated by the direction of arrow A. While the Fig. 1 is a racing bicycle with a racing handlebar 68, the present disclosure can also be applied to bicycles of any type, including full or semi-suspension mountain bikes.

[0015] The drivetrain 58 includes a chain C and a front sprocket assembly 72 coaxially mounted to a crank assembly 74 with pedals 76. The drivetrain 58 further includes a rear sprocket assembly 78 coaxially mounted to the rear wheel 56 and a rear gear change mechanism, e.g., a rear derailleur 80.

[0016] As in Fig. 1, the front sprocket assembly 72 may include one or more coaxially mounted gears, pinions, or sprockets. According to this embodiment, the front sprocket assembly 72 includes one sprocket F. One sprocket F has teeth 82 around a corresponding circumference. As shown in Fig. 1, the rear sprocket assembly 78 may include a plurality of coaxially mounted gears, pinions, or sprockets G. Each sprocket G1-G11 further includes teeth 84 arranged around a corresponding circumference. The number of teeth 84 on the rear sprockets G1-G11 may gradually decrease from the largest diameter rear sprocket G1 to the smallest diameter rear sprocket G11. Although not further described herein, a front gear changer 85 may be actuated to move from a first operating position to a second operating position to move the chain C between the front sprockets F. Likewise, the rear derailleur 80 may be actuated to move between various operating positions to shift the chain C to a selected one of the rear sprockets G1-G11.According to one embodiment, the rear sprocket assembly 78 may include more or fewer sprockets G. For example, according to one embodiment, the rear sprocket assembly 78 may include twelve or thirteen sprockets. The dimensions and configuration of the rear derailleur 80 may be adjusted to accommodate a specific plurality of sprockets. For example, the angle and length of a linkage 88 and / or a configuration of a cage 92 of the rear derailleur 80 may be adjusted to accommodate specific sprocket combinations.

[0017] The rear derailleur 80 is illustrated as a wireless, electrically actuated rear derailleur that is attached or attachable to the frame 52 or frame mount of the bicycle 50. The electrical rear derailleur 80 includes a base member 86 (e.g., a B-joint) attached to the bicycle frame 52. The linkage 88 includes two links L pivotally connected to the base member 86 in a base-linkage connection portion. A movable member 90 (e.g., a P-joint) is connected to the linkage 88 in a movable-linkage connection portion. The chain guide assembly 92 (e.g., a cage) is configured to engage and maintain tension on the chain C and includes one or more cage plates 93 having a proximal end pivotally connected to a portion of the movable member 90.The cage plate 93 can rotate or pivot about a cage rotation axis in a damping direction and a chain tensioning direction. Other gear change systems, such as mechanically or hydraulically controlled and / or actuated systems, may also be used.

[0018] A motor module with a battery may be attached to the electric rear derailleur 80. The battery supplies power to the motor module. According to one embodiment, the motor module is disposed in the movable member 90. The motor module may also be disposed elsewhere, for example, in a link L of the linkage 88 or in the base member 86. The motor module may include a gear mechanism or transmission. As is known in the art, the motor module and gear mechanism may be coupled to the linkage 88 to laterally move the cage plate 93 and thereby shift the chain C between the rear sprockets (e.g., G1-G11) on the rear sprocket assembly 78.

[0019] The cage plate 93 further includes a distal end supporting an idler gear or wheel. The wheel further includes teeth around a circumference. The cage plate 93 is biased in a chain tensioning direction to maintain tension in the chain C. The chain guide assembly 92 may further include a second gear or wheel, e.g., a guide gear, located closer to the proximal end of the cage plate 93 and the movable member 90. In operation, the chain C is guided around one of the rear sprockets (e.g., G1-G11). An upper segment of the chain C extends forward to the front sprocket assembly 72 and is guided around the one front sprocket F. A lower segment of the chain C returns from the front sprocket assembly 72 to the idler gear and is then guided forward to the guide gear. The guide gear directs the chain C to the rear sprockets (e.g., G1-G11).The lateral movement of the cage plate 93, the tensioning wheel and the guide wheel can determine the lateral position of the chain C for alignment with a selected rear sprocket (e.g. G1-G11).

[0020] The bicycle 50 may include one or more bicycle control devices mounted on the handlebar 68. The bicycle control devices may include one or more types of bicycle control and / or bicycle actuation systems. For example, the bicycle control devices may include brake actuation systems for controlling the front brake 60 and / or the rear brake 62 and / or gear shifting systems for controlling the drivetrain 58. Other control systems may also be present. For example, according to some embodiments, the system may be applied to a bicycle that utilizes only a front or only a rear gear shifter. The one or more bicycle control devices may also include suspension, seatpost, and / or other control systems for the bicycle 50.

[0021] The front wheel 54 and / or the rear wheel 56 of the bicycle 50 may include a tire 120 mounted on a radially outer tire engagement portion of a rim 122. The tire 120 may have any number of sizes. For example, the tire 120 may have a width greater than 34 mm.

[0022] As in Fig. 1 and Fig. 2, a plurality of spokes 124 are attached directly to the rim 122. Alternatively, the spokes 124 may be attached and / or secured to the rim 122 with other structural components. 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 the respective wheel 54, 56 with functional rigidity for use on the bicycle 50. The central hub 126 is configured for rotatable attachment to the bicycle frame 52.

[0023] Fig. 2 shows a bicycle wheel with a rim 122, spokes 124 and a central hub 126, e.g., the front wheel 54 of Fig. 1, removed from the bicycle 50 and without a tire. The rim 122 includes a tire engagement portion 130 that engages the tire 120, as in Fig. 1. The tire engagement portion 130 is formed radially outward of a spoke-receiving surface 132 disposed along an inner periphery 134 of the rim 122. In other words, the tire engagement portion 130 is a radially outward tire engagement portion. According to one embodiment, the tire engagement portion 130 is disposed along an outer periphery 135 of the rim 122. The tire engagement portion 130 is configured to be attached to tires that utilize clincher mounting configurations for bead-lock tires. Other configurations of the tire engagement portion 130 may also be provided to allow other types of tires to be used on the rim 122. For example, tubeless tires with bead locks may be used.

[0024] The rim 122 provides structure for attaching the spokes 124 to the rim 122 in a receiving portion of the rim 122 proximate the spoke receiving surface 132. The spoke receiving surface 132 is thus part of a spoke engaging portion 136 (e.g., a radially inner portion) of the rim 122. According to one embodiment, the spoke engaging portion 136 of the rim 122 is disposed along the inner periphery 134 of the rim 122. According to another embodiment, the spoke receiving surface 132 and the spoke engaging portion 136 may be separate parts and / or portions of the rim 122. For example, the spokes 124 may extend through the spoke receiving surface 132 and the structure for attachment to the rim 122 may be located proximate the tire engagement portion 130.

[0025] 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. The first sidewall 138 and the second sidewall extend, for example, radially outward from the spoke-engaging portion 136 to the tire-engaging portion 130. The first sidewall 138 is spaced from the second sidewall.

[0026] The rim 122 can be made from any number of materials. For example, the rim 122 can be made from metal (e.g., aluminum or an aluminum alloy). In one embodiment, at least a portion of the rim 122 (e.g., the spoke engagement portion 136 and / or the tire engagement portion 130) is formed from one or more composite materials. In one embodiment, the entire rim 122 is formed from two or more composite materials. Other configurations can also be contemplated. For example, a combination of a first composite material (e.g., natural fiber reinforced plastic or glass fiber reinforced plastic) and a second composite material (e.g., carbon fiber reinforced plastic) forms a one-piece unitary rim including the tire engagement portion 130, first sidewall 138, second sidewall, and spoke engagement portion 136 made from multiple layers of the first composite material (e.g.,glass fiber layers) and layers of the second composite material (e.g. carbon fiber layers).

[0027] The front wheel 54 and the rear wheel 56 may include rims 122 configured for any wheel size. In one embodiment, the rims 122 are configured for use on wheels that conform to the 700C bicycle wheel standard (e.g., clincher tires with a diameter of 622 millimeters and / or the International Standards Organization 622 mm).

[0028] The front wheel 54 and the rear wheel 56 can rotate in both directions around the central hub 126. As in Fig. For example, as shown in Figure 2, the front wheel 54 and the rear wheel 56 may be configured to rotate in a particular rotational direction about the central hub 126. According to another example, the front wheel 54 and the rear wheel 56 may be configured to rotate in a direction opposite to the particular rotational direction.

[0029] According to one embodiment, the first sidewall 138, the second sidewall, the spoke engagement portion 136, and the tire engagement portion 130 of the front wheel 54 and / or the rear wheel 56 of the bicycle 50 (e.g., the front wheel 54 and the rear wheel 56 in the example of Fig. 1) formed at least partially from one or more layers of the one or more composite materials (e.g., layers of composite materials). Each of the one or more layers may comprise one or more fabric plies (e.g., pieces) of the respective composite material. Different layers of different composite materials may each comprise a different number of plies or pieces of the composite materials. At least some of the layers of the composite material may have different shapes and / or sizes. Alternatively, all layers of the composite material may have the same shape and / or size.

[0030] According to one embodiment, at least some of the layers of the composite material are formed as strips. For example, strips of the one or more composite materials may form the first sidewall 138 and the second sidewall of the front wheel 54. The strips of the 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 sidewall 138 and the second sidewall of the front wheel 54 and the rear wheel 56, respectively.

[0031] In one manufacturing process, the layers of the front wheel 54 and the rear wheel 56 are integrated with the spoke engagement portion 136 and the tire engagement portion 130 (e.g., composite layers forming the spoke engagement portion 136 and the tire engagement portion 130) of the respective wheels 54, 56, for example, through a curing process, to form a one-piece, unitary rim 122. The rims 122 of the front wheel 54 and the rear wheel 56 may be formed using other manufacturing processes.

[0032] Fig. 3 and Fig. 4 show a first embodiment of a rim 200 that is aerodynamically optimized for wide-diameter tires (e.g., having a width greater than 34 mm when inflated to operating pressure). According to one embodiment, a build-up pattern of composite layers for the rim is provided prior to a curing process, for example, to form the rim 200. The layers of composite materials may be part of an integrally formed unitary rim 200 after the curing process. The resulting integrally formed unitary rim 200 may be formed from a composite laminate comprising one or more compressed layers of one or more composite materials. According to another embodiment, the rim 200 may additionally or alternatively be made at least partially of metal, such as aluminum or an aluminum alloy.According to further embodiments, the rim 200 may be made of other, additional and / or fewer materials.

[0033] The composite laminate may comprise any number of composite materials. For example, the one or more composite materials of the composite laminate may comprise a first composite material, a second composite material, a third composite material, or any combination thereof. The composite laminate may comprise more or fewer composite materials. For example, the composite laminate may comprise only the first composite material and the second composite material, or only the second composite material and the third composite material. According to one embodiment, the composite laminate comprises only the first composite material, only the second composite material, or only the third composite material.

[0034] The first composite material may comprise a matrix of a polymer-based material (e.g., a first polymer-based material) and fibers of a reinforcing material (e.g., a first reinforcing material). The first polymer-based material may be any number of materials, e.g., plastic, acrylic, resin, epoxy, or a combination thereof, and the fibers of the second reinforcing material may be any number of materials, e.g., carbon. Other polymer-based materials and / or other reinforcing fibers may also be used.

[0035] The second composite material may comprise 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 may be any number of materials, e.g., plastic, acrylic, resin, epoxy, or a combination thereof, and the fibers of the second reinforcing material may be any number of materials, e.g., fiberglass. Other polymer-based materials and / or other reinforcing fibers may also be used.

[0036] The third composite material may comprise a matrix of a polymer-based material (e.g., a third polymer-based material) and fibers of a reinforcing material (e.g., a third reinforcing material). The third polymer-based material may be any number of materials, e.g., plastic, acrylic, resin, epoxy, or a combination thereof, and the fibers of the third reinforcing material may be any number of materials, e.g., natural fibers. The fibers of the third reinforcing material may be, for example, flax fibers, kenaf fibers, hemp fibers, jute fibers, or sisal fibers. Other polymer-based materials and / or other reinforcing fibers may also be used.

[0037] The rim 200 includes a radially outward tire-engaging portion 202 (e.g., disposed along an outer periphery of the rim 200), a radially inward portion 204 (e.g., a spoke-engaging portion), a first sidewall 206, and a second sidewall 208 spaced from the first sidewall 206. The first sidewall 206 and the second sidewall 208 extend radially outward from the radially inward portion 204 to the radially outward tire-engaging portion 202. The radially outward tire-engaging portion 202 extends from the first sidewall 206 and the second sidewall 208, respectively.

[0038] The radially outward tire engagement portion 202 of the rim 200 includes a first tire retention portion 210 and a second tire retention portion 212 spaced from the first tire retention portion 210. The first tire retention portion 210 extends from the first sidewall 206, and the second tire retention portion 212 extends from the second sidewall 208.

[0039] The first tire retaining portion 210 includes a first tire retaining wall 214. According to one embodiment, the first tire retaining portion 210 further includes a first protrusion (e.g., a first tire retaining feature) (not shown). The first protrusion may extend away from the first tire retaining wall 214. The first protrusion may have any number of shapes, e.g., a shape having a rectangular cross-section with a semicircular cap. The first protrusion may extend circumferentially around the rim 200.

[0040] 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. According to one embodiment, the second tire retaining portion 212 further includes a second protrusion (e.g., a second tire retaining feature) (not shown). The second protrusion may extend away from the second tire retaining wall 216 toward the first tire retaining portion 210. The second protrusion may have any number of shapes, such as a rectangular cross-section shape with a semi-circular cap. The second protrusion may extend circumferentially around the rim 200. The first protrusion and the second protrusion may have other shapes.

[0041] The rim 200 can accommodate a tire 120 (see Fig. 1), which is, for example, a tubeless clincher tire. The tire 120 has beads that interact with the radially outward tire engagement portion 202 (e.g., the first tire retention portion 210 and the second tire retention portion 212) of the rim 200 to attach the tire 120 to the rim 200 and retain the tire 120 therein. The beads may include any number of materials within the beads, such as a steel wire or aramid fibers (e.g., Kevlar™), to prevent the tire 120 from separating from the rim 200. By being reinforced with, for example, the steel wire or Kevlar™ fiber, the beads do not expand due to internal air pressure. Alternatively, the beads may be made of the same material as the tire 120 (e.g., rubber).

[0042] The radially outward tire engagement portion 202 also includes a recess 218 disposed between the first tire retention portion 210 and the second tire retention portion 212 of the rim 200. The recess 218 provides a volume in which the beads of the tire 120 can be placed when the tire 120 is mounted on the 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 retention portion 210 and the second tire retention portion 212, respectively. When inflated, the beads of the tire 120 abut the first tire retention wall 214 and the second tire retention wall 216, respectively. For example, according to one embodiment, the first tire retention feature and the second tire retention feature hold the beads of the tire 120 in position within the radially outer tire engagement portion 202 (e.g.,They hold the beads of the tire 120 in engagement with the first tire retaining wall 214 and the second tire retaining wall 216, thereby preventing the tire 120 from separating from the rim 200. The contact between the beads and the first tire retaining wall 214 and the second tire retaining wall 216, respectively, forms a seal between the inflated tire 120 and the rim 200.

[0043] The radially outward tire engagement portion 202 may further include protrusions (e.g., bead bumps; a first bead bump and a second bead bump) on respective opposite sides of the recess 218. A first surface or step 220 (e.g., a first bead step) extends away from the first tire retaining wall 214 (e.g., between the first tire retaining wall 214 and the first bead bump), and a second surface or step 222 (e.g., a second bead step) extends away from the second tire retaining wall 216 (e.g., between the second tire retaining wall 216 and the second bead bump). According to one embodiment, curved transition regions 224 extend between the first step 220 and the first tire retaining wall 214 and the second step 222 and the second tire retaining wall 216, respectively. The bead humps may be arranged on opposite sides of the recess 218 and may be raised relative to the first step 220 and the second step 222, respectively.The bead humps can help keep the 120 tire on the 200 rim when the 120 tire loses pressure.

[0044] According to one embodiment, the layers of the one or more composite materials (e.g., the first composite material, the second composite material, and / or the third composite material) are strip-shaped. A strip of a composite material (e.g., the first composite material) of the one or more composite materials may have fibers running along a finite length of the strip. According to one embodiment, the fibers run in a primary strength direction of the strip (e.g., along the length of the strip). For example, the strip has a unidirectional fiber orientation along the length of the strip. According to another embodiment, some fibers do not run in the primary strength direction (e.g., less than 20 percent of the fibers, less than 10 percent of the fibers, or less than 5 percent of the fibers).

[0045] The strip can have any number of shapes and / or sizes. For example, the strip is rectangular. Other shapes such as square-shaped strips and non-rectangular parallelogram-shaped strips can be provided. The strip further has a width that is perpendicular to the length of the strip. The length of the strip can be defined by a size of, for example, the radially outer tire engagement portion 202, the first sidewall 206, the second sidewall 208 and / or the radially inner portion 204 of the rim 200. In other words, the length of the strip can be at least as high or wide as the radially outer tire engagement portion 202, the first sidewall 206, the second sidewall 208 and / or the radially inner portion 204 of the rim 200. According to one embodiment, the width of the strip is between 10 mm and 50 mm.The width of the strip is, for example, 30 mm. According to further embodiments, the strip is wider or narrower (e.g., 60 mm). Smaller strip widths optimize fiber alignment but are more complex to manufacture. According to one embodiment, the width of the strip corresponds to a radial width of the rim 200.

[0046] Differently shaped, wider, and / or longer layers may be used. For example, at least some of the layers of the first composite material may extend a quarter, half, or completely around the rim 200. Depending on the application in the rim, different sized and / or shaped layers of, for example, the first composite material may be used (e.g., to form an outer surface, for strength and stiffness at a highly stressed location in the rim).

[0047] The layers of the one or more composite materials may have any desired thickness. For example, the thicknesses of the layers of the one or more composite materials may be 0.4 mm or less (e.g., 0.25 mm or less). Other thicknesses of the layers of the one or more composite materials may be provided.

[0048] For example, in one or more portions of the rim 200, each of a plurality of layers of a composite material of the one or more composite materials (e.g., the second composite material) may be unidirectional. The plurality of layers of the composite material may be stacked and stitched together to form a checkerboard or diamond pattern in a layer. In other words, at least some of the plurality of layers of the composite material are each unidirectional in different directions. The thickness of such a layer may be 1.2 mm or more. Other thicknesses may be provided.

[0049] The rim 200 may have any number of shapes and sizes. For example, the rim 200 may be shaped such that a cross-section through the rim 200 and the tire is airfoil-shaped when a tire is attached to the rim 200. According to Fig. 5, the rim 200 has a thickness T and a chord length C. The thickness T is located at the widest point of the rim 200. In other words, the thickness T can be a maximum width of the rim 200 (e.g., within the Fig. 5). The chord length C is a distance between the front edge and the rear edge of the rim 200 (which, for example, partially forms the airfoil shape). In other words, the chord length C can be a maximum height of the rim 200 (e.g., within the Fig. 5 shown cross section through the rim 200).

[0050] The rim 200 can have a thickness T between 36 and 70 mm. According to further embodiments, other thicknesses T of the rim 200 can also be provided. For example, the rim 200 can have a thickness T between 30 and 70 mm.

[0051] Fig. 5 shows a mid-chord MC of the cross-section of the rim 200 (e.g., at the midpoint of the chord length C). The thickness T is located at a radial distance distal to the mid-chord MC of the cross-section of the rim 200. In other words, the thickest point of the rim 200 (e.g., the widest point within the cross-section of the rim 200) is between the mid-chord MC of the cross-section of the rim 200 and the radially outermost tire engagement portion 202 of the rim 200. According to one embodiment, the thickness T is located at a radially outermost point of the rim 200. The rim 200 may have an aspect ratio, defined by the chord length C divided by the thickness T, of greater than 1.25 but less than 3.0.

[0052] According to Fig. 5, the rim 200 has a thickness T of 40 mm and a chord length C of 54 mm, resulting in a cross-sectional ratio of 1.35. Fig. 5 further shows a 40 mm wide tire 300 mounted on the rim 200. Other rim and tire sizes may be contemplated. For example, the rim 200 may have a thickness T of 50 mm and a chord length C of 67 mm, resulting in an aspect ratio of 1.34, and a 50 mm wide tire 300 may be mounted on the rim 200. Other combinations may be contemplated.

[0053] The Fig. The rim 200 shown in Figures 3-5 is an aerodynamic rim 200 optimized for a larger tire 300 (e.g., with a tire width of 40 mm). For comparison, Fig. 6 an aerodynamic rim 400 optimized for a smaller tire 402. For example, the rim 400 may have a thickness T of 30 mm and a chord length C of 45 mm, resulting in an aspect ratio of 1.5. Fig. 6 shows a 28 mm wide tire 402 mounted on the rim 400.

[0054] The shape of the Fig. 6 is similar to the shape of the profile shown in Fig. 5. Unlike a large tire (e.g. more than 34 mm wide) mounted on a rim of standard width (e.g. 25-35 mm), both the profile of Fig. 5 as well as the profile of Fig. 6 (e.g. combined shapes of tires on rims) an airfoil cross-section and recapture the airflow split by a front edge of the respective wheel in order to minimize low pressure on the rear surfaces of the respective wheel.

[0055] According to Fig. 5, the thickness T of the rim 200 may be approximately equal to the width (e.g. a maximum width) of the tire 300 (e.g. within 5 mm for an inflated tire 300). Fig. 5 shows an axially outermost plane OP. The axially outermost plane OP is tangent to the profile of the rim 200 at the point where the thickness T (e.g., the maximum width of the rim 200) is located. The axially outermost plane OP is parallel to the chord length C. As in Fig. 5, the inflated tire 300 does not protrude beyond the axially outermost plane OP defined by the rim 200, so that the profile of Fig. 5 approximately corresponds to an airfoil cross-section. According to one embodiment, the thickness T of the rim 200 (e.g., the maximum width of the rim 200) is located at a radially outermost point of the rim 200, and the axially outermost plane OP is tangent to the profile of the rim 200 at the radially outermost point of the rim 200. In other words, the rim 200 is wider than or equal to the width of the inflated tire 300 at a junction between the inflated tire 300 and the rim 200.

[0056] Fig. 7 illustrates a method 700 for manufacturing a bicycle component (e.g., the rim 122) of a bicycle (e.g., the bicycle 50). The steps of the method 700 presented below are intended as examples. According to some embodiments, the method 700 may be performed with one or more additional steps not described and / or without one or more of the described steps. Furthermore, the order in which the steps of the method 700 are performed in Fig. 7 and described below are not to be construed as limiting.

[0057] In step 702, at least one layer (e.g., a sheet) of a first composite material is arranged in a mold. The first composite material comprises a matrix of a first polymer-based material and fibers of a first reinforcement material. According to one embodiment, the fiber orientation of the fibers of the first reinforcement material of the layer of the first composite material is unidirectional in one direction along a length of the respective layer.

[0058] 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 and have a width that is at least as large as the height of a sidewall of a rim to be manufactured. Other shapes and / or sizes can be provided.

[0059] The first polymer-based material may be or comprise any number of polymer-based materials, e.g., a thermoplastic, a thermosetting matrix, or a combination thereof. The fibers of the first reinforcement material may be or comprise any number of different types of fibers, e.g., carbon fibers, glass fibers, flax fibers, kenaf fibers, hemp fibers, jute fibers, sisal fibers, or any combination thereof. Other polymer-based materials and / or other reinforcement materials may be used for the first composite.

[0060] According to one embodiment, the layer of the first composite material is arranged in the mold such that the layer of the first composite material forms at least a portion of one of two sidewalls of the rim to be produced. According to further embodiments, the layer of the first composite material is arranged in the mold such that the layer of the first composite material forms at least a portion of another portion of the rim to be produced (e.g., a radially inner portion of the rim to be produced).

[0061] In step 704, at least one layer (e.g., a layer) of a second composite material is arranged in the mold such that the layer of the second composite material abuts and / or overlaps the layer of the first composite material. The second composite material comprises a matrix of a second polymer-based material and fibers of a second reinforcing material. The second polymer-based material may be the same as or different from the first polymer-based material, and / or the second reinforcing material may be the same as or different from the first reinforcing material.

[0062] The second polymer-based material may be or comprise any number of polymer-based materials, e.g., plastic, acrylic, resin, epoxy, or any combination thereof. The fibers of the second reinforcing material may be or comprise any number of different types of fibers, e.g., carbon fibers, glass fibers, flax fibers, kenaf fibers, hemp fibers, jute fibers, sisal fibers, or any combination thereof. Other polymer-based materials and / or other reinforcing materials may be used for the second composite.

[0063] The layer of the second composite material can have any number of shapes and / or sizes. The layer of the second composite material can, for example, be rectangular and have a width that is at least as wide as the width of the radially inner portion of the rim to be produced. Other shapes and / or sizes can be provided. According to one embodiment, the layer of the second composite material is thicker than the layer of the first composite material. According to another embodiment, the layer of the second composite material is thinner than the layer of the first composite material.

[0064] According to one embodiment, the layer of the second composite material is arranged in the mold such that the layer of the second composite material forms at least a portion of the radially inner portion of the rim to be produced. According to further embodiments, the layer of the second composite material is arranged in the mold such that the layer of the second composite material forms at least a portion of another portion of the rim to be produced (e.g., a radially outer tire engagement portion).

[0065] Steps 702 and 704 may be repeated any number of times to form a build pattern for the bicycle component. According to one embodiment, steps 702 and 704 may be repeated with one or more additional steps in which one or more layers of other composite materials are arranged any number of times, for example, to form a build pattern.

[0066] According to one embodiment, step 702 is repeated, and a further layer of the first composite material is arranged in the mold such that the further layer of the first composite material forms at least a portion of the other of the two sidewalls of the rim to be produced. Step 704 is also repeated, and a further layer of the second composite material is arranged in the mold such that the further layer of the second composite material forms at least a portion of the radially outer tire engagement portion of the rim to be produced. Steps 702 and 704 may be repeated around the inner circumference and / or the outer circumference of the rim to be produced, for example, to form a build-up pattern.

[0067] In step 706, the bicycle component is formed. Forming the bicycle component includes forming a composite laminate (e.g., laminating) comprising at least the layer of the first composite material and the layer of the second composite material in the mold. According to one embodiment, forming the bicycle component includes forming the composite laminate comprising at least the layer of the first composite material, the layer of the second composite material, and a layer of a third composite material (e.g., the same as or different from the first composite material and / or the second composite material) in the mold.

[0068] The mold can be used to form the entire bicycle component or a part of it. For example, for a rim, the mold may be divided into multiple parts to allow access to the mold when at least the layer of the first material is deposited in step 702 and the layer of the second material is deposited in step 704. For example, the mold may be divided into multiple circumferential sections (e.g., four circumferential sections) and / or multiple parts (e.g., a first sidewall piece, a second sidewall piece, and a radially outer piece).

[0069] The mold can have any number of shapes and / or sizes. For example, the mold can be shaped and dimensioned such that, after forming the composite laminate, the rim has a thickness of 40 mm and a chord length of 54 mm, resulting in an aspect ratio of 1.35. Other shapes and / or sizes of the mold can be provided.

[0070] Forming the composite laminate may, for example, comprise molding and curing the composite laminate in, for example, the mold. For example, at least the layer of the first composite material and the layer of the second composite material may be arranged and formed in the mold using a bladder that is inflated within the mold. The composite laminate may be formed in other ways.

[0071] After forming, the composite laminate can be cured by any method, for example, curing the composite laminate by pressing, in an autoclave, or in an oven, comprising at least the layer of the first composite material and the layer of the second composite material. Other curing methods may also be used.

[0072] In step 708, an opening is formed through the formed composite laminate (e.g., the radially inner portion of the radially outer tire engagement portion). For example, the opening is formed through the layer of the second composite material of the composite laminate such that the second composite material surrounds the opening.

[0073] The opening can be formed through the second composite layer of the composite laminate in any number of ways, for example by drilling the opening through the second composite layer. The opening can be formed through the second composite layer in any number of ways. For example, the opening can be formed through the second composite layer by cutting the opening out of the second composite layer. The opening can be any number of different types of openings, for example a spoke hole, a valve hole, an access hole, or another type of opening.

[0074] Step 708 may be repeated any number of times. For example, step 708 may be repeated for the other layer of the second composite material (e.g., as another valve hole or an access hole) and all other layers of the second composite material through which an opening is to extend (e.g., for spoke holes or access holes).

[0075] According to an embodiment in which the layer of the second composite material extends completely around the composite laminate of the rim to form at least a portion of the radially inner portion of the rim or the radially outer tire engagement portion of the rim, step 708 may 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.

[0076] The plurality of openings can be formed in any number of configurations through the layer of the second composite material. For example, the plurality of openings can 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 the radially inner portion of the rim). Other configurations of the plurality of openings can be provided.

[0077] The illustrations of the embodiments described herein are intended to provide a general understanding of the structure of the various embodiments. The illustrations are not a complete description of all elements and features of devices and systems employing the structures or methods described herein. Many other embodiments will be apparent to those skilled in the art upon review of the disclosure. Other embodiments may be utilized and derived from the disclosure, so that structural and logical substitutions and changes may be made without departing from the scope of the disclosure. Furthermore, the illustrations are merely representative and may not be drawn to scale. Certain proportions in the illustrations may be exaggerated, while other proportions may be reduced.Accordingly, the revelation and the figures are to be considered as illustrative rather than restrictive.

[0078] While this description contains numerous details, these should not be construed as limitations on the scope of the invention or the claimed subject matter, but rather as descriptions of features specific to particular embodiments of the invention. Certain features described in this description in connection with individual embodiments may also be implemented in combination in a single embodiment. Conversely, various features described in connection with a single embodiment may also be implemented in multiple embodiments separately or in any suitable subcombination.Furthermore, where features are described above as operating in certain combinations and even originally claimed as such, one or more features from a claimed combination may in some cases be taken out of the combination, and the claimed combination may be directed to a sub-combination or variation of a sub-combination.

[0079] Although the drawings illustrate and describe operations and / or steps in a particular order, this should not be understood to mean that these operations must be performed in the order shown or in sequential order, or that all of the operations shown must be performed to achieve the desired results.

[0080] One or more embodiments of the disclosure may be referred to herein individually and / or collectively by the term "invention," without intending to limit the scope of this application to any particular invention or inventive concept. Although specific embodiments are shown and described herein, any arrangement that achieves the same or similar purpose may be substituted for the illustrated embodiments. This disclosure is intended to cover all later adaptations or variations of the various embodiments. Combinations of the above embodiments and other embodiments not specifically described herein will be apparent to those skilled in the art upon review of the specification.

[0081] The Summary of the Disclosure is provided in accordance 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. Furthermore, in the foregoing Detailed Description, various features may be grouped together or described in a single embodiment to simplify the disclosure. This disclosure should not be construed to imply that the claimed embodiments require more features than are expressly recited in each claim. Rather, as will be apparent from the following claims, the inventive subject matter may be directed to fewer than all of the features of any of the disclosed embodiments. Therefore, the following claims are incorporated into the Detailed Description, with each claim standing on its own and separately defining the claimed subject matter.

[0082] The foregoing detailed description is intended to be considered as illustrative rather than restrictive, and it is the following claims, including all equivalents, that are intended to define the scope of the invention. The claims are not to be construed as limiting the described order or elements unless expressly stated. Therefore, all embodiments falling within the scope and spirit of the following claims and their equivalents are claimed as the invention. QUOTES CONTAINED IN THE DESCRIPTION

[0000] This list of documents submitted by the applicant was generated automatically and is included solely for the convenience of the reader. This list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions. Cited patent literature

[0000] US 63 / 618,594

[0001]

Claims

[1] Rim for a bicycle wheel, the rim comprising: a radially inner portion disposed along an inner circumference of the rim; a first side wall; a second side wall spaced from the first side wall, the first side wall and the second side wall extending radially outward from the radially inner portion; and a radially outer tire engagement portion disposed along an outer periphery of the rim, the radially outer tire engagement portion extending from the first sidewall and the second sidewall, respectively, where the maximum width of the rim is between 30 mm and 70 mm and the rim has an aspect ratio of more than 1.25 but less than 3.

0. [2] The rim of claim 1, wherein the rim has a chord length extending between a leading edge and a trailing edge of the rim, the maximum width of the rim being at a radial distance distal to a midchord of a cross-section of the rim. [3] A rim according to claim 2, wherein the maximum width of the rim is between the central chord and the radially outer tire engagement portion. [4] A rim according to any one of the preceding claims, wherein the maximum width of the rim is located at a radially outermost portion of the rim. [5] A rim according to any one of the preceding claims, wherein the rim has a chord length extending between a front edge and a rear edge of the rim, the maximum width of the rim being 40 mm and the chord length being 54 mm, the aspect ratio being 1.

35. [6] A rim according to any one of the preceding claims, wherein the rim has a chord length extending between a front edge and a rear edge of the rim, the maximum width of the rim being 30 mm and the chord length being 45 mm, the aspect ratio being 1.

5. [7] A rim according to any one of the preceding claims, wherein the maximum width is located where an axially outermost plane is tangent to one of the first and second sidewalls of the rim. [8] Rim according to one of the preceding claims, wherein the rim is made of a carbon fiber composite material. [9] Wheel for a bicycle, the wheel comprising: a rim comprising: a radially inner portion disposed along an inner circumference of the rim; a first side wall; a second side wall spaced from the first side wall, the first side wall and the second side wall extending radially outward from the radially inner portion; and a radially outer tire engagement portion disposed along an outer periphery of the rim, the radially outer tire engagement portion extending from the first sidewall and the second sidewall, respectively, wherein a tire having a width of more than 34 mm when inflated is attachable to the rim such that a width of the tire when the tire is attached to the rim is less than or equal to a maximum width of the rim, the maximum width of the rim being between 30 mm and 70 mm and the rim having an aspect ratio of more than 1.25 but less than 3.

0. [10] The wheel of claim 9, wherein the rim has a chord length extending between a leading edge and a trailing edge of the rim, the maximum width of the rim being at a radial distance distal to a mid-chord of a cross-section of the rim. [11] A wheel according to claim 10, wherein the maximum width of the rim is between the central chord and the radially outer tire engagement portion. [12] A wheel according to any one of claims 9 to 11, wherein the maximum width of the rim is located at a radially outermost portion of the rim. [13] A wheel according to any one of claims 9 to 12, wherein the rim has a chord length extending between a front edge and a rear edge of the rim, the maximum width of the rim being 40 mm and the chord length being 54 mm, the aspect ratio being 1.

35. [14] A wheel according to any one of claims 9 to 13, wherein the rim has a chord length extending between a front edge and a rear edge of the rim, the maximum width of the rim being 30 mm and the chord length being 45 mm, the aspect ratio being 1.

5. [15] A wheel according to any one of claims 9 to 14, wherein the maximum width is located where an axially outermost plane is tangent to one of the first and second sidewalls of the rim. [16] Wheel according to one of claims 9 to 15, wherein the rim is made of a carbon fiber composite material.

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