METHOD FOR PRODUCING A BICYCLE COMPONENT AND BICYCLE COMPONENT

Description

[0001] The present invention relates to a method for producing a bicycle component having at least one component body, which is formed at least partially from at least one fiber composite material in at least one mold, and to such a bicycle component. Bicycle components made of fiber composite materials offer a particularly low weight relative to their strength and are therefore often used in competition-oriented sports bicycles.

[0002] US 2015 / 096672 A1 describes a method for producing a rim in which the brake flanks are made of a different material than the rest of the rim. First, a preform made of carbon fiber composite material is produced using a mold. Then, a resin is applied to the preform in the area of ​​the (future) brake flanks, and both are reinserted into the mold. The resin is bonded to the preform under heat and pressure, so that the rim and the brake flanks are finally formed and firmly connected. It is proposed to roughen the mold in the area of ​​the brake flank so that the future brake flank has a rough surface. This is intended to improve the friction properties of the brake flank. The roughened mold can be used both for producing the preform and for bonding the preform and the brake flank.The roughened preform is intended to improve the adhesion properties of the resin to the preform.

[0003] However, after the component body has been formed, extensive post-processing is often necessary to eliminate imperfections such as small depressions, craters, or grooves. While these surface defects generally do not compromise stability, they are clearly visible even to the naked eye. Therefore, post-processing is usually required to optimize the optical quality and, for example, to meet the specific requirements of high-end bicycle components.

[0004] To fill the craters and create a flat or smooth surface, a filler compound is often applied. Alternatively, or additionally, unevenness can be mechanically removed. This is usually followed by a coat of varnish to give the surface a uniform finish. To ensure the varnish adheres reliably, this is usually preceded by sanding.

[0005] In contrast, the object of the present invention is to provide an inexpensive and at the same time reliable solution with regard to the previously discussed surface defects in the production of bicycle components.

[0006] This object is achieved by a method having the features of claim 1 and by a bicycle component having the features of claim 15. Preferred developments of the invention are the subject of the subclaims. Further advantages and features of the present invention will become apparent from the exemplary embodiment.

[0007] The method according to the invention serves to produce a bicycle component with at least one component body. The bicycle component is intended in particular for a bicycle that is at least partially powered by human power. The component body is formed at least partially, in particular completely, from at least one fiber composite material in at least one molding tool (in particular for the first time or originally). In particular, the component body is at least partially, in particular completely, initially formed from the fiber composite material in the molding tool, i.e., it is given its initial shape therein. In particular, this results in the (prepared and) not yet solidified or soft (and in particular still shapeless with regard to the final shape of the component body; however, the fiber composite material can have a targeted fiber orientation and / or fiber layering or lamination, e.g.Prepregs can be provided) fiber composite material of the component body is produced or originally / first formed. Such initial shaping is also referred to as primary shaping. In this case, at least one molding area of ​​the molding tool used to shape at least one outer section of the component body is specifically provided with at least one surface roughness. In particular, by means of the surface roughness of the molding area, a targeted surface roughness for the outer section is also produced during (in particular simultaneously with) the production of the outer section. Preferably, the surface roughness is incorporated into the molding area. In this case, the molding area is roughened to a mean roughness value of at least 1 micrometer and a maximum of 4 micrometers. In particular, this counteracts surface defects in the molded outer section.

[0008] The method according to the invention offers many advantages.

[0009] The surface roughness in the molding area is particularly advantageous because it reliably prevents defects in the surface of the molded outer section. The targeted creation of surface roughness in the molding tool significantly increases the uniformity and optical quality of the surface. This eliminates the need for complex surface finishing after the molding process. As a result, the outer area immediately after molding has a surface roughness created by the surface roughness of the molding area. This means that the outer section already has a completely or at least largely finished surface immediately after molding. Another particularly advantageous feature is that the incorporation of the surface roughness into the molding tool is particularly inexpensive. Overall, the invention can achieve a high visual quality and / orHigher quality optical appearance of the surfaces of bicycle components can be achieved particularly economically and reliably.

[0010] Preferably, a rim for a wheel for a bicycle that is at least partially powered by human power is produced as a bicycle component. In particular, the rim comprises at least one rim body that provides the component body. In particular, the rim body is formed at least partially from the fiber composite material in the mold. In particular, the outer section is part of the rim body. In such an embodiment, the method can be used particularly advantageously. Rims with a particularly uniform and defect-free surface can thus be produced very inexpensively.

[0011] Preferably, within the scope of the present invention, the term "bicycle component" can be replaced by the term "rim" and the term "component body" can be replaced by the term "rim body".

[0012] In particular, the rim body comprises at least one rim flank and preferably at least two rim flanks. In particular, the rim flanks each extend laterally along the rim. In particular, the rim flanks are arranged axially on the rim. In particular, the rim flanks extend in the radial direction and extend circumferentially around the rim. It is possible for the rim flanks to meet at a radially inner end of the rim body and / or at a radially outer end of the rim body. There, the rim flanks can be connected to one another directly or indirectly via at least one further structure, e.g., a rim base or rim well.

[0013] It is possible for the rim body to comprise at least one rim base and / or at least one rim well. In particular, at least two rim flanks are provided connecting the rim base to the rim well. The outer section is provided in particular by the rim flanks and / or the rim base and / or the rim well. In particular, the outer section extends over the entire outer side of the rim body visible in the intended state and preferably over at least one and in particular both rim flanks and / or the rim base and / or the rim well. The rim flanks can each have a rim flange.

[0014] The rim body is in particular provided by at least one separately formed part. It is possible for the rim body to consist of at least two separately formed parts which are joined together. In this case, it is possible for each part to have at least one of the rim flanks. The outer section can extend over both parts or just over one part. In particular, the parts are formed successively in one forming tool or simultaneously in different forming tools. In particular, the forming tools which serve to form a part provided with the outer section are then each equipped with at least one forming region with the surface roughness.

[0015] The bicycle component is intended, in particular, for a bicycle that is at least partially powered by human power. A hub and / or fork and / or seat post and / or brake and / or handlebars and / or stem and / or frame can also be manufactured as a bicycle component. In particular, a hub shell and / or fork bridge and / or fork leg and / or seat post tube and / or brake arm and / or handlebar tube and / or stem tube and / or frame section then provide the component body. Accordingly, it is possible that the term "bicycle component" can be replaced by the respective terms "hub," "fork," "seat post," "brake," "frame," and "handlebar."

[0016] In all embodiments, it is particularly preferred that at least the outer section is coated, preferably painted. In particular, the outer section is coated at least partially and preferably substantially completely, in particular completely. A partially transparent or transparent coating is preferably applied. This is particularly advantageous because an optimal coating can be achieved on the outer section produced according to the invention even without pretreatment. For example, filling or filling can be dispensed with.

[0017] In particular, at least one coating, preferably at least one lacquer coating, is applied. The coating comprises, in particular, at least one layer. The lacquer coating comprises, in particular, at least one lacquer layer and / or at least one base layer and / or at least one top layer. In particular, the lacquer layer is arranged above the base layer and / or below the top layer.

[0018] Particularly preferably, the molding area is provided with a surface roughness that is suitable and designed to improve the adhesion of a coating to be applied. Thus, in addition to the aforementioned advantages, significantly improved coating adhesion or paint adhesion is achieved without significant additional effort. In such a configuration, the surface roughnesses described within the scope of the present invention are particularly suitable and can be used advantageously. In particular, the surface roughness is adapted to the coating to be applied and, for example, to its requirements for the surface to be coated.

[0019] Preferably, the outer section is coated after forming in the mold, without having previously undergone a surface treatment, in particular an abrasive one. In particular, the outer section is coated in the state in which it was formed in the molding area of ​​the mold. Such a configuration is particularly economical and, due to the surface roughness in the molding area, simultaneously leads to particularly optimal coating results. Abrasive surface treatment is understood to mean, in particular, mechanical and / or non-mechanical treatments, for example, machining, chemical, electrochemical, or thermal treatment processes.

[0020] Preferably, at least one outwardly closing coating, in particular a paint, is applied directly to the outer section. This allows the weight to be reduced considerably. In particular, the outer section is in a state in which it was formed in the molding area of ​​the mold. In particular, an outwardly closing coating is applied without a prior coating, for example a primer or the like. In particular, no filler and / or putty or the like is applied beforehand. Tests have shown that due to the targeted surface roughness in the molding area, a particularly high surface quality of the coating and, in particular, considerably improved adhesion of the coating can be achieved. However, it is also possible for at least one coating to be provided below the outwardly closing coating.For example, a primer or the like may be provided.

[0021] The molded area is roughened in particular to a mean roughness (Ra) of at least 1 µm and preferably at least 1.1 µm and particularly preferably at least 1.2 µm. A mean roughness of at least 1.3 µm or at least 1.4 µm or at least 1.5 µm or at least 1.6 µm or at least 1.7 µm or at least 1.8 µm or at least 1.9 µm is also advantageous and preferred. Such lower limits for the mean roughness have proven to be particularly advantageous. Mean roughness values ​​of at least 0.5 µm or at least 0.6 µm or at least 0.7 µm or at least 0.8 µm or at least 0.9 µm can also be provided. The mean roughness indicates in particular the average distance of a measuring point on the surface from a center line. The mean roughness corresponds in particular to the arithmetic mean of the absolute deviation from the center line. Mean roughness values ​​of at least 2 µm, at least 2.2 µm, or at least 2.5 µm are also possible and advantageous.Average roughness values ​​of at least 2.8 µm or at least 3 µm or at least 4 µm can also be provided.

[0022] In particular, the mold area is roughened to a maximum mean roughness of 4 µm, preferably 3 µm, and particularly preferably 2.8 µm. It is possible and advantageous for the mold area to be roughened to a maximum mean roughness of 2.5 µm, preferably 2.2 µm, and particularly preferably 2 µm. The maximum mean roughness can also be 1.9 µm or 1.8 µm. Such upper limits for the maximum mean roughness have proven particularly advantageous in tests.

[0023] Average roughness values ​​between 1.3 µm and 1.9 µm, preferably between 1.4 µm and 1.8 µm, and particularly preferably between 1.5 µm and 1.7 µm, have proven particularly advantageous for the molding area. For example, an average roughness value of 1.6 µm is provided. A mean roughness value of 1.8 µm has also proven advantageous for certain molding tool alloys. In particular, the average roughness value is also adapted to the molding tool alloy.

[0024] It is possible that the previously mentioned mean roughness values ​​may be subject to deviations in the range of + / - 0.1 µm or + / - 0.2 µm. It is possible and advantageous for the outer section to have a surface roughness with a mean roughness value as previously specified for the surface roughness of the mold area.

[0025] In particular (and in particular also for technical reasons), the outer section has a surface roughness with a mean roughness value that is greater by a defined amount than the mean roughness value for the surface roughness of the molding area. In particular, the outer section has a surface roughness with a mean roughness value between 1.8 µm and 5.8 µm and preferably between 2.8 µm and 4.8 µm and particularly preferably between 3.5 µm and 4.0 µm. For example, a mean roughness value of 3.8 µm is provided for the outer area. In this case, the outer section has, in particular, a surface roughness with an average surface roughness (Rz) between 20 µm and 30 µm and, for example, of 25 µm with a maximum surface roughness (Rz max) of 33 µm. Such values ​​can be advantageously implemented with the previously described surface roughness of the molding area.

[0026] The surface roughness of the molding area is created in particular by means of at least one mechanical and / or non-mechanical removal process. Preferably, the surface roughness of the molding area is created by means of at least one laser texturing process. In particular, the molded outer section has a laser texture. This allows for an economical and, at the same time, particularly targeted creation of the roughness.

[0027] It is also preferred and advantageous for the surface roughness of the molded area to be created using at least one blasting process (also referred to as blasting), and particularly preferably by shot peening. This also offers an economical and, at the same time, particularly targeted method for creating the roughness. It has been shown that, under certain conditions, shot peening can offer particular advantages over laser texturing. Other suitable blasting processes are also possible. The blasting particles used in the blasting process can also have a geometry other than spherical.

[0028] Suitable combined processes, e.g., shot peening and laser texturing, are also possible. The processes presented within the scope of the present invention are therefore disclosed in particular in one and / or combination. In all embodiments, it is preferred that the molded area be polished before creating the surface roughness.

[0029] A mechanical removal process is understood in particular to mean suitable separation processes. For example, at least one machining process can be used. A machining process with a geometrically undefined cutting edge is possible, for example grinding, abrasive blasting, and preferably shot peening. A machining process with a geometrically defined cutting edge can also be provided, for example milling or the like. As a non-mechanical removal process, thermal, chemical, electrical, and / or electrochemical removal can be provided, for example. For example, erosion and / or etching can be provided. Other suitable roughening processes are also possible.

[0030] In particular, at least one laser is moved across the molding area in a raster-like pattern and / or with varying intensity and / or speed and / or frequency. In particular, the molding area is thereby provided with overlay structures. In particular, the overlay structures have the same or a deliberately different surface roughness than the rest of the molding area. In particular, even with different surface roughness, the mean roughness for the overlay structures and for the rest of the molding area lies within the previously defined value range. In particular, the overlay structures themselves are larger than the mean roughness of their surface roughness by a factor of 10 and preferably at least by a factor of 100 or even by a factor of 500 or more. With such overlay structures, defects in the surface of the outer section can be avoided particularly reliably.

[0031] The overlay structures particularly comprise overlay lines. In particular, the overlay structures are each provided by at least one overlay line. The overlay lines are particularly arranged at least partially spaced apart. In particular, the overlay lines at least partially intersect. The overlay lines can be at least partially rectilinear or have a curved course. Overlay structures that are at least partially planar are also possible. It is possible for the overlay structures to be at least partially (only very slightly) recessed and / or raised relative to their surroundings.

[0032] The mold is preferably equipped with venting chimneys. The venting chimneys are preferably suitable and designed to counteract the formation of air inclusions and in particular air bubbles and / or dry spots (areas without sufficient matrix material) during molding in the mold. In particular, the occurrence of air inclusions is counteracted by allowing any air present between the mold area and the outer section to escape along the venting chimneys. In particular, the occurrence of dry spots is also counteracted by distributing a matrix material of the fiber composite material (e.g. resin) via the venting chimneys. Such venting chimneys achieve a particularly high-quality surface of the outer section, which requires little or almost no post-processing after demolding.

[0033] The mold area with the surface roughness can extend only over the vent holes, so that the vent holes provide the mold area. The areas of the mold outside the mold area are then polished. However, the vent holes can also extend only over a portion of the mold area. In this case, the vent holes can have the same or a deliberately different surface roughness than the rest of the mold area. In particular, the mean roughness value for the vent holes and for the rest of the mold area then lies within the previously defined value range. The vent holes can run radially and / or tangentially across the rim flank.

[0034] Particularly preferably, the vent chimneys are provided by the overlay structures or are part of the overlay structures. In particular, the vent chimneys are manufactured as previously described for the overlay structures. In particular, the vent chimneys have a geometry as previously described for the overlay structures. The vent chimneys can also be manufactured in other ways.

[0035] The molding region is preferably arranged in the molding tool such that the outer section extends over at least 50% and preferably at least 75% of an outer side of the component body. The molding region can also be arranged in the molding tool such that the outer section extends over at least 90% of the outer side. The outer section can also extend completely over the outer side of the component body. It can be provided that the outer section extends over at least 20% or at least 30% or at least 40% of the outer side of the component body. The previously stated surface areas particularly preferably relate to an outer side of at least one rim flank and preferably both rim flanks of the rim body. In particular, the previously stated surface areas relate to an outer surface visible in a properly assembled state of the bicycle component.

[0036] In a particularly advantageous embodiment, the molding region is arranged in the molding tool such that the outer section extends at least over the rim flanks. The molding region is preferably arranged in the molding tool such that the outer section is arranged at least radially below a braking flank and / or at least radially below a center line of the rim flank. It is also advantageous and preferred that the molding region is arranged in the molding tool such that the outer section extends at least radially above a center line of the rim flank. In particular, the outer section is formed in this way on both rim flanks. In particular, the outer section extends at least over the rim flanks and / or at least over the rim base and / or at least over the rim bed. This offers many advantages in the production of particularly high-quality rims.

[0037] If the rim has at least one braking flank, the outer portion extends in particular at least outside the braking flank and preferably also over the braking flank. The manufactured rim may also have no braking flanks and be designed, for example, as a rim for disc brakes.

[0038] It is possible for the forming tool to have at least one brake flank forming region arranged outside the forming region for forming at least one brake flank. Preferably, the brake flank forming region is equipped with friction elements that are at least 10 times larger, at least 100 times larger, or even 500 times larger, than the mean roughness of the surface roughness of the forming region. The friction elements comprise, in particular, elevations and / or depressions. The size of the friction elements relates, in particular, to the height or depth of elevations or depressions.

[0039] It is possible and advantageous for the friction elements themselves or the brake flank forming region itself to be provided with a surface roughness as described above. In this case, the surface roughness extends in particular also over the brake flank forming region. In this way, in addition to the braking effect, the friction elements also offer particularly good visual quality or particularly good adhesion for a coating. It is also possible for the friction elements in the brake flank forming region not to be provided with any specific surface roughness. In this case, the brake flank forming region can have, in addition to the friction elements, a reduced and / or increased surface roughness or the same surface roughness as the forming region. In particular, the rim comprises at least one brake flank formed by means of such a brake flank forming region.

[0040] In particular, the molding area is provided with a consistent surface roughness. It is also advantageous for the molding area to be provided with a constant surface roughness. In particular, a consistent mean roughness is provided. This enables particularly cost-effective creation of the molding area and, at the same time, the production of particularly uniform surfaces. The molding area can also be provided with at least two different surface roughnesses. The mean roughness values ​​of the different surface roughnesses preferably lie within the previously defined value ranges.

[0041] It is also possible and preferred for the molding area to be equipped with at least two or a plurality of different surface roughnesses. This offers a particularly inexpensive way to create surface sections on the component body with varying degrees of matte or glossy finishes. It is also possible for the different surface roughnesses to specifically influence the reflective behavior of coatings and, for example, paint finishes.

[0042] It can be provided that the forming area comprises forming elements for forming raised and / or recessed ornaments on the outer section. In this case, the surface roughness extends in particular also over the forming elements. This allows the ornaments to be provided with a particularly high visual quality without any effort. In particular, the ornaments have the same surface roughness as the outer section. This also avoids surface defects in the ornaments and saves on costly reworking. However, it is also possible for the forming elements to lie outside the forming area and / or not to be provided with the surface roughness. In particular, the ornaments have structures which are at least 10 times larger and preferably at least 100 times larger or even 500 times larger than the mean roughness of the surface roughness of the forming area.

[0043] It is possible that the mold elements deliberately have a lower and / or higher surface roughness than the rest of the outer section in order to create a different degree of gloss and / or mattness on the component body.

[0044] This allows the ornaments to be highlighted with minimal effort. It also eliminates the need for paint, saving weight and improving the environmental impact.

[0045] Particularly preferably, after removal of the component body from the mold, at least one surface treatment of the outer section is provided to reduce and / or eliminate unevenness. This surface treatment is preferably replaced by the targeted incorporation of the surface roughness into the mold area. This surface treatment can thus be performed even before the component body is formed. This offers a significant improvement in both production and the product.

[0046] The bicycle component according to the invention comprises at least one component body. The component body is formed at least partially from at least one fiber composite material in at least one mold. At least one outer portion of the component body has a deliberately created surface roughness (in particular simultaneously with its initial shaping). Such a bicycle component also achieves the object of the invention particularly advantageously.

[0047] The bicycle component according to the invention is manufactured, in particular, using the method according to the invention. However, it is also possible and advantageous for the bicycle component according to the invention to have a surface roughness produced using another suitable method. For example, the surface roughness can be created by at least one mechanical and / or non-mechanical removal process following the forming in the mold. An at least partially automated and, in particular, controlled abrasive blasting process is preferred for this purpose. Other removal methods are also possible.

[0048] Preferably, the surface roughness of the outer section is arranged at least partially and in particular completely beneath at least one coating. In particular, the outer section is arranged at least partially and in particular completely beneath the coating. In particular, the bicycle component comprises at least one coating arranged above the surface roughness. It is also possible for the surface roughness of the outer section to be at least partially exposed. In particular, the outer section is arranged in a part of the component body that is visible in the intended assembled state. The outer section itself does not have to be visible.

[0049] The surface roughness is in particular designed as previously described for the method. In particular, the surface roughness has the properties described above. In particular, the surface roughness has the roughness parameters described above and preferably the mean roughness values. In particular, the surface roughness is arranged on the bicycle component as described above. In particular, the coating is also designed as described above. In particular, the outer section is arranged and in particular designed as described above. The bicycle component is in particular at least partially equipped with the properties as previously described in the context of the method. The bicycle component according to the invention is in particular a rim.

[0050] In the context of the present invention, surface roughness is understood in particular to mean a shape deviation of at least the third order, preferably at least the fourth order, and in particular the third to fifth order. In particular, surface roughness is not understood to mean a shape deviation of the first and / or second order. It is possible that surface roughness is not understood to mean a shape deviation of the third order. In particular, for the definition of shape deviation and / or surface roughness, the statements according to DIN 4760 (as of the filing date) are incorporated in their entirety into the disclosure by reference.

[0051] In particular, surface roughness is not understood to mean a macroscopic and / or naked-eye pattern. In particular, surface roughness does not include any macroscopic and / or naked-eye individual structural elements, such as elevations and / or depressions. In particular, surface roughness is understood to mean a surface appearance that is macroscopically and / or naked-eye perceptible as a continuously roughened surface. In particular, surface roughness does not mean ornaments or individual structures that are specifically perceptible to the naked eye.

[0052] By providing the molding area with the surface roughness, a targeted surface roughness of the outer section is also created. In particular, the outer section has a surface roughness that is generated by the surface roughness of the molding area. In particular, the surface roughness of the outer section has the same parameters, or at least approximately the same parameters, as the surface roughness of the molding area.

[0053] In particular, the outer section is arranged in a region of the component body that is visible in the finished state of the component body. The outer section arranged in the visible region may itself be invisible.

[0054] For example, the outer section can be arranged under a coating or the like. It is also possible that the outer section itself is visible.

[0055] In particular, the molding area is understood to be the area of ​​the molding tool that forms the outer portion of the component body. The molding tool may comprise additional areas for forming other portions of the component body. In particular, the outer portion is understood to be the portion of the component body that has a surface roughness generated by the surface roughness of the molding area.

[0056] Preferably, the surface roughness of the molding area is suitable and designed to counteract the formation of air inclusions and in particular air bubbles and / or dry spots (areas without sufficient matrix material) during molding in the mold. In particular, the occurrence of air inclusions is counteracted by the fact that air present between the molding area and the outer section is distributed over the entire surface along the (roughened) outer section and can escape there, in particular. In particular, the occurrence of dry spots is counteracted by the fact that a matrix material of the fiber composite material (e.g. resin) is distributed over a larger area or more evenly along the (roughened) molding area. The surface roughnesses of the molding area described here can be advantageously used for this purpose.

[0057] Preferably, the surface roughness of the molding region is suitable and designed to create a surface roughness on the outer section that at least partially optically obscures or covers surface defects of the outer section (visible to the naked eye). In particular, the surface roughness of the molding region creates a surface roughness on the outer section that makes the molding region appear matte or matted. In particular, the surface roughness of the molding region prevents a shine on the outer section. The surface roughnesses of the molding region described here can be advantageously used for this purpose.

[0058] In the context of the present invention, the surface defects are in particular those which arose during the production of the component body in the mold.

[0059] Further advantages and features of the present invention will become apparent from the description of the embodiments which are explained below with reference to the accompanying figures.

[0060] The figures show: Fig. 1 is a purely schematic side view of a bicycle; Fig. 2 is a highly schematic representation of a bicycle component produced according to the invention in a molding tool in a sectional view; Fig. 3 is a highly schematic representation of a bicycle component according to the invention in a sectional view; Fig. 4 is a highly schematic representation of another bicycle component produced according to the invention in a molding tool in a sectional view; and Fig. 5 is a highly schematic representation of a molding tool in a side view.

[0061] The Figure 1shows a bicycle 101 configured as a racing bike with a bicycle component 10 manufactured according to the method according to the invention. The bicycle 101 can also be configured as a mountain bike or as another type of bicycle. In any embodiment, the bicycle 101 can be muscle-powered or partially muscle-powered and, for example, configured as an e-bike. The bicycle component 10 is provided here, for example, by the rims 1 of the wheels 100 of the bicycle 101.

[0062] The bicycle 101 has two wheels 100, each equipped with a hub 102 and a rim 1. The bicycle 101 comprises a frame 104 and a fork 105, each of which holds one of the wheels 100. Furthermore, the bicycle 101 comprises a seat post 106 with a saddle 107 attached thereto and a handlebar 108, which is attached to the frame 104 via a stem 109. Furthermore, the bicycle 101 has a disc brake system with two brakes 103. As part of a pedal drive 110, the bicycle 101 here comprises a derailleur.

[0063] With reference to the Figure 2 The method according to the invention for producing the bicycle component 10 is presented in more detail using the example of a rim 1.

[0064] The rim here comprises, as component body 20, a rim body 2, which is formed by a rim base 12 and a rim well 32 as well as two rim flanks 22 connecting the rim base 12 to the rim well 32. At a radially outer region of the rim body 2, the rim flanks 22 merge into rim flanges 62.

[0065] The rim 1 is formed from a fiber composite material in a mold 3, also referred to as a mold. The mold 3 is made up of several parts. In the illustration shown here, the rim body 2 is formed and is still in the mold. 3. Two parts of the forming tool 3 are still attached to the rim body 2, which serve, among other things, to form the rim flanks 22. Other parts of the forming tool 3 have already been removed.

[0066] The fiber composite material comprises, in particular, at least one fiber material and at least one matrix material. For example, the fiber material comprises carbon fibers, glass fibers, aramid fibers, or other suitable fiber materials. The matrix material comprises, for example, at least one thermosetting plastic and / or at least one thermoplastic plastic or another suitable material. For example, an epoxy resin can be used.

[0067] In order to be able to form the rim 1 with a particularly high surface quality, the forming tool 3 is equipped with a forming area 13 with a targeted surface roughness 5. The forming area 13 serves to form an outer section 4 of the rim body 2. The forming area 13 is arranged here such that the outer section 4 extends along the outer or visible side of the rim flanks 22 and the rim base 12. The outer section 4 extends here both radially above and radially below a center line 52 of the rim body 2 or the rim flanks 22.

[0068] Due to the surface roughness 5 in the molding area 13, the molded outer section 4 exhibits a particularly high visual quality, free of undesirable surface defects. Complex post-processing after removal from the mold 3 to remove surface defects on the outer section 4 can be dispensed with.

[0069] Alternatively, the outer section 4 can also extend only over a part of the outer surface of the rim body 2 shown here, for example only in sections over the rim flanks 22. A correspondingly arranged forming area 13 is then provided in the forming tool 3.

[0070] The molding area 13 shown here, for example, is provided with a surface roughness 5 with a mean roughness Ra between 1.4 µm and 1.9 µm, and preferably with a mean roughness between 1.6 µm and 1.7 µm. Other suitable roughnesses can also be provided. The surface roughness 5 of the molding area 13 is transferred accordingly to the outer section 4 formed with it.

[0071] Such a surface roughness 5 has proven particularly advantageous in tests. For example, a significant reduction in undesirable air inclusions between the mold area 13 and the outer section 4 during the curing of the rim body 2 was achieved. This is a particularly advantageous effect because it allows problematic resin-poor zones on the visible surface to be reduced or even completely avoided. Furthermore, due to the surface roughness 5 in the mold area 13, a significantly improved paint adhesion was also observed during subsequent painting processes of the rim 1.

[0072] For example, the surface roughness 5 is created by means of a laser treatment, so that the molding area 13 receives a laser texturing 15. Other methods for surface texturing in the molding tool 3 are also possible, for example, blasting processes or the like.

[0073] The rim 1 can also be provided, in a construction not shown in detail here, by at least two rim parts, each with at least one rim flank 22. The rim parts are then manufactured, for example, in separate molds 3, each with a molding area 13, or even sequentially in the mold 3. The rim parts are then joined together.

[0074] The Figure 3 shows the related to the Figure 2 described rim body 2 after removal from the mold 3. The outer section 4 was provided with a coating 6 and, for example, a paint finish.

[0075] Due to the surface roughness 5 in the mold area 13 and the resulting surface roughness 5 also formed on the outer section 4, the coating 6 could be applied without prior mechanical or non-mechanical surface treatment of the outer section 4. For this purpose, the surface roughness 5 in the mold area 13 was selected to improve the adhesion of the coating 6 to be applied. However, it is also possible that the rim 1 already has the final visual quality after removal from the mold 3 and does not receive a coating 6.

[0076] Here, coating 6 was also applied in areas that are later not visible underneath a tire.

[0077] The rim 1 shown here can also be a bicycle component 10 that is equipped with a surface roughness that is not manufactured according to the method according to the invention. For example, the surface roughness 5 on the outer section 4 can be achieved by an automated and controlled abrasive blasting process downstream of the molding process.

[0078] The Figure 4 shows a design of the related to the Figure 2described method, wherein the rim 1 is equipped with brake flanks 42. To form the brake flanks 42, the forming tool 3 is equipped with brake flank forming areas 33. Friction elements (not shown in detail here) are arranged in the brake flank forming areas 33, which form a friction surface on the rim body suitable for rim brake pads. The friction elements comprise, for example, elevations and / or depressions that are more than 100 times larger than the mean roughness value of the surface roughness 5 of the forming area 13.

[0079] Depending on the desired surface quality of the brake flank 42, the brake flank shape area 33 can also be provided with the surface roughness 5 or can have a different or no targeted surface roughness 5.

[0080] Additionally or alternatively, the rim 1 is provided with ornaments 7 and, for example, lettering, a logo, or the like. To produce the ornaments 7, the molding area 13 has mold elements 23, which serve as a negative mold of the desired ornament 7.

[0081] The surface roughness 5 extends over the shaped elements 23. This also achieves a particularly high visual quality for the ornaments 7. Furthermore, a particularly favorable adhesion for a coating 6 is also achieved on the ornaments 7.

[0082] However, it can also be provided that the shaped elements 23 are arranged outside the molding area 13 and do not have any surface roughness 5. For example, this can be used to create targeted matte / glossy surfaces. Thus, the ornaments 7 can be highlighted particularly easily due to the lack of surface roughness 5.

[0083] The Figure 5shows a molding tool 3 in which the molding area is equipped with overlay structures 8 to prevent air pockets and dry spots without matrix material. The geometry of the overlay structures 8 is sketched purely schematically here. The overlay structures 8 are part of a laser texture 15 and are generated by means of targeted guidance or rasterization of the laser. The overlay structures 8 have a surface roughness 5 that is essentially the same as the rest of the molding area 13. If required, however, a design with a deliberately different surface roughness 5 can also be provided.

[0084] The mold 3 is also equipped with venting chimneys 18 to more effectively counteract the formation of air pockets and dry spots. The venting chimneys 18 are part of the molding area 13 and are provided by the overlay structures 8. The venting chimneys can also have orientations or geometries other than those sketched purely schematically here.

[0085] The invention presented here offers a significant and, at the same time, particularly inexpensive improvement in paint adhesion. Furthermore, mechanical (e.g., sanding) or chemical (e.g., priming) pretreatment prior to painting can be dispensed with. Furthermore, considerably fewer coats of paint are required to achieve a durable finish. As a result, the manufactured bicycle component 10 has a significantly reduced weight, which is particularly advantageous for competition bicycles. Furthermore, coatings 6 or paint finishes can even be omitted entirely. Due to the significantly improved visual quality already after demolding, subsequent operations can be eliminated. This results in particularly high effectiveness and, at the same time, a favorable environmental balance. The invention also offers significantly improved reproducibility.

[0086] It has been shown that the invention can also significantly improve decal application and / or adhesion. Particular advantages have also been demonstrated with a single-coat finish without a clear coat. With the invention, only a flame treatment can be performed during the coating process, eliminating the need for baking cycles, resulting in significant savings.

[0087] In addition to or alternatively to the rim 1, another bicycle component 10 of the bicycle 101 can also be manufactured according to the method described here. For example, the hub 102, the brake 103, the frame 104, the fork 105, the seat post 106, the handlebar 108, and / or the stem 109 can represent a bicycle component 10 manufactured according to the invention, the component body 20 of which is formed in a suitable mold 3. List of reference symbols:

[0088] 1 rim 42 brake flank 2 Rim body 52 center line 3 mold tool 62 Rim flange 4 Outdoor section 100 balance bike 5 Surface roughness 101 Bicycle 6 Coating 102 hub 7 ornament 103 brake 8 Overlay structure 104 Frame 10 Bicycle component 105 Fork 12 Rim base 106 seat post 13 Form area 107 saddle 15 Laser texture 108 handlebar 18 Ventilation chimney 109 stem 20 Component body 22 rim flank 23 Form element 32 Rim bed 33 Brake flank shape area

Claims

1. Method of manufacturing a bicycle component (10) having at least one component body (20), formed at least partially of at least one fibrous composite material in at least one shaping mold (3), wherein at least one shaping area (13) of the shaping mold (3), which serves to shape at least one outer section (4) of the component body (20), is provided with at least one intended surface roughness (5), and wherein the surface roughness of the shaping area also serves to provide an intentional surface roughness for the outer section during the generation of the outer section, characterized in that the shaping area (13) is roughened to an average roughness of at least 1 micrometer and maximally 4 micrometers, in particular to inhibit surface imperfections of the shaped outer section (4).

2. The method according to the preceding claim, wherein the bicycle component (10) manufactured is a rim (1) for a wheel (100), and wherein the rim (1) comprises at least one rim body (2) having at least two rim flanks (22), providing the component body (20).

3. The method according to any of the preceding claims, wherein the outer section (4) is coated after shaping, without first being subjected to an abrasive surface treatment, and wherein an in particular outwardly finishing coating (6) is applied directly on the outer section (4).

4. The method according to any of the preceding claims, wherein the shaping area (13) is roughened to an average roughness of maximally 3 micrometers.

5. The method according to any of the preceding claims, wherein the surface roughness (5) of the shaping area (13) is generated by means of shot peening and / or by means of laser texturing, so that the shaped outer section (4) shows a laser texture (15).

6. The method according to the preceding claim, wherein at least one laser is moved across the shaping area (13), in particular by way of raster scanning and / or at various intensities and / or velocities and / or frequencies, and wherein the shaping area (13) is thus provided with overlay structures (8), and wherein the overlay structures (8) show a surface roughness (5) that is the same as, or intentionally different from, the rest of the shaping area.

7. The method according to any of the preceding claims, wherein the shaping mold (3) is provided with vent flues (18), and wherein the shaping area (13) provided with the surface roughness (5) only extends over the vent flues (18), or wherein the vent flues (18) only extend over a subrange of the shaping area (13).

8. The method according to the preceding claim and according to claim 6, wherein the vent flues (18) are provided by the overlay structures (8) and / or are generated like the overlay structures (8).

9. The method according to any of the preceding claims, wherein the shaping area (13) is disposed in the shaping mold (3) such that the outer section (4) extends over at least 50% and preferably at least 75% of an outside surface of the component body (20), preferably of at least one rim flank (22) of the rim body (2).

10. The method according to claim 2, wherein the shaping area (13) is disposed in the shaping mold (3) such that the outer section (4) extends at least over the rim flanks (2) and preferably at least radially beneath a brake flank (42) and / or the centerline (52) of the rim flank (22).

11. The method according to claim 2, wherein the shaping mold (3) comprises at least one brake flank shaping area (33), and wherein the brake flank shaping area (33) is provided with friction members, which are larger than the average roughness of the surface roughness (5) of the shaping area (13) at least by a factor of 100.

12. The method according to any of the preceding claims, wherein the shaping area (13) is provided with a continuous and / or constant surface roughness (5), or wherein the shaping area (13) is provided with at least two different surface roughnesses (5).

13. The method according to any of the preceding claims, wherein the shaping area (13) comprises mold elements (23) for forming elevated and / or recessed ornaments (7) on the outer section (4), so that the surface roughness (5) also extends over the mold elements (23).

14. The method according to any of the preceding claims, wherein after removing the component body (20) from the shaping mold (3), at least one surface treatment of the outer section (4) is provided for reducing unevennesses, and wherein the surface treatment is replaced by controlled providing of the shaping area (13) with the surface roughness (5).

15. Bicycle component (10) comprising at least one component body (20), manufactured according to the method according to any of the preceding claims.