TOOLING DEVICE AND METHOD FOR PRODUCING A RIM

Description

[0001] The invention relates to a tooling device for producing a rim made of fiber composite material for vehicles, in particular bicycles, which are regularly at least partially muscle-powered in their intended use, a rim produced therewith, and the use of the tooling device for production. Rims made of fiber-reinforced plastics are known in the prior art, with which the weight of the rims can be reduced. At the same time, such rims achieve comparable or even greater stability than metal rims with a lower overall weight. A disadvantage of such rims, however, is their complex production, since many production steps must usually be carried out by hand, which leads to higher costs. Furthermore, the many manual process steps are prone to errors, which increases the scrap rate and further increases manufacturing costs.On the other hand, the volumes of high-quality bicycle rims produced are not large enough to make the development and implementation of a fully automated production facility worthwhile. It has been found that the strength of the manufactured rims does not always meet expectations.

[0002] EP 1 231 077 A2 and CN 10179865 A disclose devices and methods for producing bicycle rims from fiber composite materials. These devices utilize elastic molds placed between the rim flanges on the rim base to facilitate easier removal of the molds after the finished rim has cured. This is because the rim flanges often protrude axially inward in the area of the rim flanges, forming an undercut. This facilitates production. However, the strength of rims produced with these materials does not always meet expectations.

[0003] It is therefore the object of the present invention to provide a tool device and its use for producing a rim made of fiber composite material, with which rims of better quality and preferably a lower reject rate can be produced.

[0004] This object is achieved by a tool device having the features of claim 1 and by the use claim 10. Preferred developments and refinements of the invention are the subject of the respective subclaims. Further advantages and features of the present invention will become apparent from the general description and the description of the exemplary embodiments.

[0005] A tool device according to the invention is used to produce a rim for at least partially muscle-powered vehicles and in particular bicycles, wherein the rim has opposing rim flanks, a rim well and a rim base, and rim flanges formed on the (radially outer ends of the) rim flanks. In particular, the rim flanks (sidewalls) meet at the radially innermost point. The tool device comprises two forming devices and a ring device. The ring device comprises a unit designed as a ring unit, and the forming devices each comprise a unit designed as a forming unit. The forming devices each have contact surfaces for forming at least part of a rim flank and the outer visible surface of the rim flanges. The ring device serves to form the rim well and the axially inwardly oriented surfaces of the rim flanges.The ring device comprises a ring unit made of a less elastic material and at least one ring cover made of a more elastic material and the mold devices each comprise a mold unit made of a less elastic material and at least one mold cover made of a more elastic material that can be applied thereto.

[0006] In particular, the wall thickness of the coating is between one-eighth (and preferably one-quarter) of the minimum wall thickness of the rim well of the rim to be manufactured and eight times (and preferably four times) the minimum wall thickness of the rim well of the rim to be manufactured. The wall thickness of the coating is between 0.1 mm and 10 mm.

[0007] The ring device comprises a ring unit made of a less elastic material and at least one ring cover made of a more elastic material. Alternatively or additionally, the molding devices each have a mold unit made of a less elastic material and at least one mold cover made of a more elastic material that can be applied thereto. This means that either a ring cover is present or mold covers are present on the mold units, or both a ring cover on the ring unit and mold covers are present on the mold units.

[0008] The invention has many advantages. A significant advantage is that the rim flanges are formed between the forming devices and the ring device. The ring device comprises the less elastic ring unit and the more elastic ring coating, and / or the forming devices have a more elastic mold coating (particularly in the area of the rim flange). This allows optimal pressure to be exerted on the rim flange during production. A wall thickness of the coating between 1 / 8 and 8 times the minimum wall thickness of the rim base ensures reliable function. Wall thicknesses between 0.1 mm and 10 mm are very advantageous for bicycle rims.

[0009] The mold units are also made of a less elastic material than the ring cover or the mold cover. This allows the ring cover and / or the mold cover to elastically yield and build up and transmit the necessary pressure to the rim flanges and / or the rim base. The more elastic material of the ring cover and / or the mold cover ensures, on the one hand, that overloading does not occur and, on the other hand, that sufficient pressure is generated. If two very hard and rigid materials form the space for the rim flange, too much material can lead to overloading and thus to fiber displacement and even malformations in the rim flange. On the other hand, too little material can lead to hollow spots and air pockets, which can weaken the material.

[0010] Naturally, an ideal amount of material is not always available. The invention now allows for compensation. If there is (slightly) too much material, the pressure on the rim flange wall is increased, and the more elastic material of the ring coating and / or the mold coating is compressed more strongly. If there is (slightly) less fiber composite material, the pressure is (slightly) reduced, and the more elastic material of the ring coating and / or the mold coating is compressed less strongly. In both cases, with certain deviations, sufficient pressure can still be applied, allowing the production of a rim of high and improved quality.

[0011] According to the invention, the ring coating is present and mold coatings are provided. Then, a harder material is used on one side and a softer material on the other. Particularly preferred is the ring coating rather than the mold coating. However, the combined use of ring and mold coatings is also possible in principle.

[0012] In any case, a sufficiently high pressing force can be applied at any point on the rim. There is no limitation caused by one fixed tool part hitting another.

[0013] The appearance and strength can be improved. A suitable compaction can be achieved in the rim flange area. The tooling preferably offers a harder surface on the molding device and a counterpart with a more elastic surface on the ring coating, beneath which, in turn, a harder surface is present on the ring unit, or vice versa. The elastic side expands with temperature and ensures a good bond between the individual fiber layers in the flange area.

[0014] This allows for the elimination of possible (minor) inclusions and defects. Delamination in the horn region due to insufficient compaction can also be avoided. The surface quality in the horn region can be improved. Better interlaminar bonding of the individual layers in the horn region and higher mechanical and structural properties can be achieved.

[0015] The tool setup now optimally presses the rim flange. Two hard tool parts are no longer pressed together or pressed against the fiber layers from both sides. At least one pressing surface is more elastic than the other.

[0016] The rim base (rim belly) and the lower rim flanks (rim sides) are preferably pressed against the (usually solid) mold units by an inflatable tube or bladder, or a core that expands (under temperature). In these areas, compaction by the individual fiber layers (e.g., carbon layers and especially prepreg layers) is sufficient.

[0017] The rim base is preferably pressed radially outward against the ring assembly, and in particular the ring cover. This prevents any contact between a fixed tool and a fixed tool (via the fiber layers) in any area. Adequate compression can be ensured.

[0018] This allows the rims produced with it to better exploit their potential in terms of mechanical and structural properties and strength.

[0019] To ensure good compaction in the rim flange area, at least one solid, hard tool part is covered or replaced with an elastic material, or provided with a ring coating. This elastic material generates the necessary pressing force to compact the flange area during the pressing process at elevated temperatures.

[0020] A significant advantage is that every area of the rim is pressed. At least one side of the rim wall is pressed by a tool or medium.

[0021] Preferably, the material of the ring coating is more elastic than the material of the mold units, or the ring coating is more elastic than the mold units. The mold units then provide the precise outer shape of the rim flanks and rim flanges, and the axially inner sides of the rim flanks are compacted in a flexible and elastic manner.

[0022] The ring device (and in particular the ring unit) preferably comprises a plurality of circumferentially assembled ring segments. The ring device preferably has a contact surface in the radially inner region for forming the rim well. The contact surface for forming the rim well can be formed directly on the ring unit. It is possible and preferred for the ring coating to form or provide the contact surface for forming the rim well. The ring coating can be formed in one piece around the entire circumference or consist of two or more segments.

[0023] The tooling is very advantageous and offers the possibility of producing high-quality and reproducible rims, especially for bicycles.

[0024] In preferred embodiments, the annular covering comprises at least one (elastic or more elastic) compression ring, which is particularly adapted to the inner shape of the rim flange(s). Preferably, the annular device comprises two separate and axially spaced (elastic) (circumferential) compression rings. However, the annular covering can also extend continuously from one rim flange to the other, so that only one compression ring is present, covering the inner surfaces of both rim flanges and also the rim base.

[0025] Preferably, a ratio of the elastic coefficients of the materials of the ring unit (mold unit) and the ring coating (mold coating) is greater than 2 or greater than 5. The ratio of the elastic coefficients can also reach and exceed 10, 20 or 50 or 100 or 1000 or 5000 or 10000. Preferably, the elastic coefficient or the elastic modulus of the ring coating (mold coating) is less than 5 or 1 or 0.1 GPa. The elastic modulus of the ring unit and / or the elastic modulus of the mold units is preferably greater than 5 or 10 or 25 or 50 GPa. The elastic modulus of the ring coating is preferably between 0.1 MPa and 5 GPa (between 0.1 and 5000 megapascals) and in particular between 0.3 and 30 MPa.

[0026] Preferably, the ring coating and the mold coating consist at least in part of a material taken from a group of materials comprising rubber-like materials and silicone materials.

[0027] In particular, the ring unit consists at least predominantly of at least one metallic material, and particularly preferably, the ring unit consists (essentially or entirely) of a light metal. Preferably, the ring unit forms a core. The ring unit (or the core) preferably consists of a stronger and / or less elastic material than the ring coating. The ring coating preferably consists of a more elastic material than the ring unit. The same preferably applies to a mold unit and the mold coating.

[0028] The ring coating and / or the mold coatings consist, in particular, at least partially of a rubber-elastic or rubber-like material. The ring coating and / or the mold coatings particularly preferably consist at least partially, substantially, or almost entirely of a silicone material. The use of silicone elastomers, polyurethanes, and / or at least one silicone rubber is possible.

[0029] It is preferred that the thickness (wall thickness) of the ring coating and / or the mold coatings be greater than 0.5 mm and / or less than 5 or 7 mm. In particular, the wall thickness in the radially central region of the rim flange is between 1 mm and 5 mm and can be, for example, 3 mm or 4 mm. A minimum wall thickness ensures that an elastically compressible compensation volume is available. A maximum wall thickness ensures precise shaping of the component.

[0030] The thickness of the ring coating and / or the mold coatings can also depend on the elasticity coefficient (elastic modulus). If the elasticity coefficient is lower and the ring coating or mold coatings are therefore more elastic, the wall thickness of the coating is preferably selected to be smaller than if the elasticity coefficient of the ring coating or mold coatings is higher. A product of the elasticity coefficient of the ring coating / mold coatings and the wall thickness can be a measure (for assessment). If elasticity is greater, the wall thickness is reduced and vice versa. The wall thickness can be used, for example, as the wall thickness in a typical area of the ring coating or, for example, in the radially central area of the rim flange or rim well. An important aspect is that the specified shape is maintained. Deviations in the wall thickness in the finished rim of more than 10% (or 5%) are generally undesirable.

[0031] Particularly preferably, the thickness of the annular coating and / or the molded coatings is thicker or greater than half the axial wall thickness or width of the rim flange (in a radially central region) and / or thinner than three or five times the axial wall thickness or width of the rim flange. In particular, the wall thickness (thickness) of the annular coating and / or the molded coatings is at least (approximately) the axial width of the rim flange (in a central region) and / or is less than three or two times the axial width (wall thickness) of the rim flange.

[0032] To produce two rims with different dimensions, the same ring unit can be used with different ring covers. For example, if the axial width differs by only 1 mm or 2 mm, a different ring cover with a slightly thicker wall thickness can be selected. If necessary, a disc ring can be inserted to compensate for the width, or a different center section of the ring unit with an adjusted width can be used.

[0033] Particularly preferably, the mold units and / or the ring unit consist of (at least) one light metal and (and / or) are, in particular, machined and / or processed. Preferably, the mold units and / or their units are polished on the contact surfaces with the rim to be produced. This further increases the quality of the rim to be produced.

[0034] In particular, the tooling device comprises at least one auxiliary mold part, which, together with one of the ring devices, forms a molding surface for the rim base. It is also possible to provide an auxiliary mold part for each of the molding devices. In this case, one of the molding devices with the associated auxiliary mold part can be used selectively.

[0035] It is possible and preferred for the molding devices and / or the ring device and / or the auxiliary mold part to have corresponding alignment units. This allows for reproducible alignment of the individual molding devices and the ring device or the auxiliary mold part to be ensured. For fastening the molding devices and the ring device or the auxiliary mold part to one another, appropriate fastening means are provided, which can be mounted on corresponding fastening openings or on the alignment units. For example, screws, pins, rivets, clamps, locking parts, or the like can be used as fastening means.

[0036] In all embodiments, it is preferred that the molding devices and the ring device each have a weight of less than 35 kg, in particular less than 30 kg or less than 25 kg, and particularly preferably less than 20 kg or 15 kg. In particular, at least one mold device has a weight of less than 15 kg, less than 12 kg, or less than 10 kg. Preferably, the two mold devices and the ring device, in the assembled state, have a total weight of less than 35 kg, less than 30 kg, or even less than 20 kg. This enables one person to move the individual units and the tool device as a whole, even alone and without outside assistance. This facilitates production.

[0037] Because the tooling includes compact molds and a compact ring unit, which are manufactured as turned or milled parts, the manufacturing costs for a single tooling setup are significantly reduced. This allows for the use of a larger number of tooling setups for parallel production. Higher-quality rims can be produced at lower costs, and these also require very little or no rework of the visible surfaces.

[0038] A use according to the invention is carried out using a tool device. The tool device is used to produce a rim for at least partially muscle-powered vehicles, and in particular bicycles, wherein the tool device is designed as described above.

[0039] The applicant reserves the right to claim a procedure.

[0040] The method according to the application serves to produce a rim made of fiber composite material with opposing rim flanks, a rim well and a rim base, and rim flanges formed on the (radially outer ends of the) rim flanks for (in intended and typical operation) at least partially muscle-powered vehicles, and in particular bicycles. It is carried out using a tooling device as described above. The tooling device has two molding devices, for example, a left-hand molding device and a right-hand molding device. The tooling device further comprises a ring device.

[0041] The procedure is carried out with the following steps in this or another sensible order: One of the two forming devices is selected and provided. The forming device comprises a flank contact surface for forming a lateral (and, for example, the left or right) rim flank. (At least) a first fiber layer of the at least one fiber composite material is applied to the flank contact surface of the selected forming device, which forms the visible layer of at least a predominant part of the visible surface and in particular almost the entire or the entire visible surface of the associated (and, for example, left) rim flank. The other forming device is provided, which comprises a flank contact surface for forming the other (and opposite) lateral rim flank. This rim flank can, for example, form the right rim flank or, conversely, the left rim flank.(At least) a first fiber layer of the at least one fiber composite material is applied to the flank contact surface of the other forming device, which as a visible layer forms at least a predominant part of the visible surface and in particular almost the entire or the entire visible surface of the other rim flank. A plurality of ring segments are connected to form a ring unit and provided with at least one ring coating, so that a ring device with a (radially inner) circumferential rim well contact surface and contact surfaces for the rim flanges is created, wherein at least a first fiber layer of the fiber composite material is applied, which forms the rim well. The ring device is placed on one of the molding devices (for example, the left or right molding device). The other molding device (correspondingly, the right or left molding device) is placed thereon, and the ring device and the molding devices are connected to one another. The fiber composite material is solidified and, in particular, cured, and the ring segments and the

[0042] The molding devices are removed, and the rim is removed. Another or modified method according to the application for producing a rim with opposing rim flanks, a rim base and a rim bottom, and rim flanges formed on the rim flanks made of fiber composite material for at least partially muscle-powered vehicles, and in particular bicycles, is carried out using a tool device with two molding devices, e.g., a left-hand molding device and a right-hand molding device, and with a ring device. The molding devices each have a molding unit and a mold cover. The following method steps are carried out in this or another sensible order: One of the two molding devices is selected and provided. A mold coating is applied thereto, so that a molding device with a flank contact surface for forming a lateral rim flank is provided. (At least) a first fiber layer of the at least one fiber composite material is applied to the flank contact surface of the selected molding device, which forms the visible layer of at least a predominant part of the visible surface and in particular almost the entire or the entire visible surface of the associated (and, for example, left) rim flank. The other mold unit is provided, and a mold coating is applied thereto, so that the other molding device is provided with a flank contact surface for forming the other (and opposite) lateral rim flank.This rim flank can, for example, form the right rim flank or, conversely, the left rim flank. (At least) a first fiber layer of the at least one fiber composite material is applied to the flank contact surface of the other forming device, which, as a visible layer, forms at least a predominant part of the visible surface and, in particular, almost all or the entire visible surface of the other rim flank. A plurality of ring segments are connected to form a ring unit (and optionally provided with at least one ring coating), so that a ring device is created with a (radially inner) circumferential rim well contact surface and contact surfaces for the rim flanges, wherein at least a first fiber layer of the fiber composite material is applied, which forms the rim well. The ring device is placed against one of the forming devices (for example, the left or right forming device).The other mold (i.e., the right or left mold, respectively) is placed on top of it, and the ring assembly and the molds are connected to each other. The fiber composite material is solidified and, in particular, cured. The ring segments and the molds are removed, and the rim is removed.

[0043] The rim is now essentially finished (according to the different and combinable variants).

[0044] Afterwards, spoke holes can be made if necessary.

[0045] In the processes, in particular the coating (mold coating, ring coating) is provided with a wall thickness which is in particular between one eighth of the minimum wall thickness of the rim base and / or the rim flange and eight times the minimum wall thickness of the rim base and / or the rim flange.

[0046] The method according to the application has many advantages. A significant advantage of the method according to the invention is that, during normal operation, the outer visible surfaces are (directly) shaped and formed by the molding devices, onto which the first fiber layers are placed. The rim flanges are formed between the ring coating of the ring device and the mold coatings of the molding devices. At least one of the contact surfaces of the rim flange is designed to be more elastic. This ensures a homogeneous, reproducible, and full-surface contact of the fiber layers with the molding devices of the tooling device.

[0047] Because the entire visible outer surface of the finished rim is created by surfaces directly adjacent to the molding equipment, the surface quality of the rim flanks can be significantly improved. The number of air pockets and other defects can be significantly reduced, thus significantly lowering the scrap rate. The process is less prone to defects. Fiber distortion in the fiber layers can also be reduced and largely avoided, thereby increasing the quality and stability of the rim manufactured in this way. The position and orientation of the fibers in the outer fiber layers is defined at all times, which improves stability and appearance.

[0048] The improved appearance of the finished rim makes it possible to produce the rim "out of the mold." Due to the clearly defined shape and position of the fiber layers and the fibers within them, defects in the cured rim can be significantly reduced.

[0049] In the prior art, however, methods are known in which fiber layers are first inserted into an auxiliary tool. A pre-formed bundle of fiber layers is then transferred into the actual tool mold and inserted there. During the transfer of the fiber layers, individual fibers and fiber layers can shift, meaning that the position and shape of the individual fiber layers is not always reproducible. However, one of the reasons why the process has been carried out in this way to date is that the actual tool mold is so heavy that it cannot easily be transported manually by one person (or several people). With the invention, however, the individual parts of the tool device can each be easily transported separately by a single person. Therefore, the placement of the visible layers and also the reinforcement layers can take place directly into the mold.

[0050] Preferably, the fiber layers are inserted into the tool units, and the outer layers visible on the finished rim are pressed directly onto the tool units. Preferably, the respective forming devices completely form the visible area of the rim flanks. The ring device preferably forms the visible area of the rim well.

[0051] In a preferred embodiment, the fiber layers are pressed against the forming devices of the tooling to ensure full-surface contact between the fiber layers and the flank contact surfaces. This prevents air pockets and defects, thus increasing quality.

[0052] In particularly preferred developments, all fiber layers, which form the visible outer surfaces as visible layers during intended use, are pressed against the forming devices and the ring device of the tooling device to ensure full-surface contact between the fiber layers and the flank contact surfaces. This can improve structure and quality.

[0053] Reworking the visible surface, and in particular repainting the outer surface to conceal air pockets and other defects, can be avoided. This results in a particularly advantageous process. Because repainting the visible surfaces is not necessary, another process step can be eliminated, thereby reducing costs. Another significant advantage is that the overall weight of the rim can be reduced, as the weight of the applied layer is eliminated.

[0054] In particularly advantageous embodiments, an auxiliary mold part of the tooling device is used. In this case, an auxiliary mold part of the tooling device that matches the selected molding device is connected to the previously selected molding device, so that the (selected) molding device, together with the auxiliary mold part, forms a (common) molding surface for the rim base that extends around a symmetry axis of the rim. The molding surface for the rim base is formed in regions on the selected molding device and in regions on the auxiliary mold part.

[0055] In this embodiment, the first fiber layer is not only applied to the flank contact surface of the selected molding device, but the first fiber layer is also applied (in one piece) to the rim base region of the auxiliary molded part in order to form a continuous first fiber layer in the rim base region. This continuous first fiber layer extends not only over the rim base region of the (selected) molding device, but also over the rim base region or rim base molding region of the auxiliary molded part. Thus, the first fiber layer is preferably applied continuously to the flank contact surface of the selected molding device and to the rim base region of the auxiliary molded part, so that a continuous and one-piece first fiber layer is provided in the rim base region. These developments produce a particularly stable and high-quality rim.

[0056] In preferred developments, the auxiliary molded part is subsequently removed from the selected molding device, and (immediately thereafter or preferably later) the two molding devices covered with fiber layers are connected to one another. The removal of the auxiliary molded part is carried out with such care that the draped fiber layers in the area of the rim base retain (approximately or at least substantially) their shape. The sections of the fiber layers projecting from the selected molding device in the area of the rim base, together with the fiber layers placed on the other molding device, form the other rim flank. However, the "projecting" sections do not form a visible surface on the finished rim.

[0057] It is preferred that after removing the auxiliary mold part, the ring device is first applied and that the other mold device is then applied.

[0058] In simple embodiments, the selected forming device is placed on a horizontal table, for example, for covering with fiber layers, and the first fiber layer and, if necessary, further fiber layers are placed on the flank contact surface of the selected forming device and, if necessary, the auxiliary forming part and pressed against the respective contact surfaces. Parallel to this, or after this, or before this, the other forming device is placed on a horizontal table, for example, and the other forming device is covered with a first fiber layer, and, if necessary, further fiber layers are placed on the other forming device.

[0059] Parallel to this, or before or after this, the ring device can be covered with the corresponding fiber layers. After the auxiliary mold part has been removed, the ring device with the fiber layers applied to the rim well contact surface is placed on the selected mold device. Subsequently or after this, the other mold device with the applied fiber layers can be placed on the selected mold device and the ring device. In this configuration, the mold devices are each placed step by step on a horizontal table. However, it is also possible for the table to be arranged at an angle to the horizontal, or for the mold devices to be positioned vertically in space and the fiber layers to be pressed onto the corresponding mold devices from the side.

[0060] In preferred developments, the first fiber layer applied to the selected molding device forms the visible layer with the visible surface of the associated rim flank in the area of the flank contact surface, and a reinforcement layer of the rim base in the rim base area of the auxiliary molded part, rather than the visible layer with the visible surface of the other rim flank. This achieves an advantageous connection between the two halves. The two halves of the rim can be symmetrical or asymmetrical.

[0061] Preferably, the visible rim base is formed by the radially inner regions of the rim flanks or by the radially inner regions of the first fiber layers, which are applied to the selected forming device or the other forming device.

[0062] In advantageous embodiments, the two molding devices and the auxiliary molding part each have a parting surface running perpendicular to a symmetry axis of the rim. The molding devices and the auxiliary molding part can be selectively placed against each other at the parting surface. Thus, the auxiliary molding part is preferably first placed against the selected molding device and removed again after the corresponding fiber layers have been applied. Subsequently, the other molding device with the associated parting surface is placed against the parting surface of the selected molding device.

[0063] Preferably, at least one reinforcement layer (at least in the area of the rim base) is introduced into the interconnected molding devices.

[0064] Particularly preferred is a sequence of process steps in which the auxiliary molding part is placed on the selected molding device. After the first fiber layers have been applied, the auxiliary molding part is removed, and the ring device with the previously applied fiber layers is placed on top. Finally, the other molding device with the applied or applied fiber layers is placed on top.

[0065] In all embodiments, rim flanges are formed on both rim flanks. In particular, at least one rim flange is formed at least partially by fiber layers applied to one of the forming devices and to the ring device. This means that a rim flange is preferably formed by fiber layers applied to a forming device as well as by fiber layers applied to the ring device. This increases stability.

[0066] In advantageous developments, at least one fiber strand is inserted for reinforcement in the intersection area of the rim well and the rim flank. Such a fiber strand can consist of a plurality of filaments or a bundle of filaments, or can comprise such filaments. It is also possible, for example, to use filaments braided into a plait or filaments connected to a cord or twisted around each other as the fiber strand. Such inserted fiber strands can reinforce the intersection areas of the rim well and the rim flank, as well as the rim flange.

[0067] In all embodiments, it is preferred that the ring device comprises at least two and in particular three or more ring segments in the circumferential direction. Particularly preferably, three ring segments are present in the circumferential direction. It is also possible to use only two ring segments, which then each extend over an angle of 180°. Preferably, three ring segments are used, so that each individual ring segment extends over a circumferential angle of significantly less than 180°. Preferably, the ring segments are designed identically, so that with three ring segments each preferably covers an angular range of 120°. It is also conceivable for the individual ring segments to extend over different angular ranges. Overall, the ring segments extend over the entire circumference.

[0068] The ring device preferably comprises at least two, and in particular three or more, ring segments in the axial direction (parallel to the rim's axis of symmetry) transversely to the circumferential direction. Thus, it is possible for the ring device to consist of a total of nine ring segments. Three ring segments each form a ring. The three rings (each with three ring segments) are arranged one after the other in the axial direction. The ring segments can be offset from one another in the axial direction. The ring segments together form the ring device, which forms the rim well contact surface radially inward.

[0069] The axially central ring segments can, in particular, be wedge-shaped. This makes it possible for the central ring segments to be removed first after production. Subsequently, the other ring segments can be removed, which, for example, form an undercut at the rim flanges to provide radially inwardly projecting ends of the rim flanges.

[0070] However, it is also conceivable that the axially middle ring segments form a disc-shaped ring rather than a wedge shape. Even then, the axially outer ring segments can form an undercut at the rim flanges.

[0071] In advantageous embodiments, a locking ring is provided, which is placed externally around the interconnected molding devices and the ring device. The locking ring can be applied radially from the outside and reinforce the cohesion of the components. In this respect, the locking ring can also be referred to as an outer clamping ring. It is also possible to dispense with a locking ring, especially if the molding devices and the ring device are connected to each other by other means.

[0072] Preferably, the tooling device equipped with the fiber layers is evacuated before curing. Particularly preferably, the tooling device is inserted into a pressing device and / or heated. This can assist the consolidation or curing of the fiber composite material.

[0073] In all embodiments, it is particularly preferred that fiber layers impregnated with at least one resin are used. Such fiber layers provided with or impregnated with matrix material (in particular resin) can also be referred to as prepregs and preferably have an amount of matrix material (and preferably resin) that is (at least substantially) sufficient for curing. The use of prepregs is particularly advantageous. It is also conceivable that matrix material or resin material is (additionally) introduced into the fully equipped tool device. For example, matrix material or resin material can be injected or sucked in. It is also possible to use fiber layers, fiber mats, fabric mats or the like as prepregs and additionally introduce (some) resin material.

[0074] In all embodiments, it is preferred that an inflatable tube is inserted (in the area of the future hollow chamber) before the molding devices are connected to the ring device. Preferably, the tube is inflated after the molding devices have been attached to the ring device. A connection to the outside for inflation, for example, forms the future valve opening. This allows the tube to be removed later.

[0075] It is preferred that spoke holes are made after the rim has been removed from the tooling device.

[0076] A rim according to the invention for at least partially human-powered vehicles, and in particular bicycles, has opposing rim flanks, a rim well and a rim base, and rim flanges formed on the (radially outer ends of the) rim flanks. The rim flanks, in particular, meet at the radially innermost point. The rim is manufactured from at least one fiber composite material using a previously described method and a previously described tooling device. In a preferred embodiment, the outer surface visible during normal operation consists at least predominantly or entirely of the at least one fiber composite material. This applies apart from any rim eyelets and type information and, for example, stickers that are small compared to the rim surface, wherein the factor of the area of, for example, stickers to the rim surface is less than 1 / 5, 1 / 10, or 1 / 100.

[0077] The rim according to the invention is very advantageous and offers a high surface quality and a reproducible and high quality even without post-processing of the outer surface and in particular without painting the outer surface.

[0078] In all embodiments, a rim produced with the tool device and / or the described method is intended in particular for wheels equipped with a disc brake and in particular does not require a braking flank.

[0079] In particular, the rim is or will be designed to be bulbous. The rim can have a V- or U-shape. Preferably, a widest point of the rim lies between the radially outer end of the rim (at the rim flanges) and a radially inner end at the rim base. For this purpose, the tool device is preferably designed to be correspondingly bulbous.

[0080] Further advantages and features of the present invention will become apparent from the embodiments which are explained below with reference to the accompanying figures.

[0081] The figures show: Figure 1 shows a schematic representation of a mountain bike with rims according to the application; Figure 2 shows a schematic representation of a racing bike with rims according to the application; Figure 3 shows a schematic overall view of a tool device according to the application for producing a rim according to the application; Figure 4 shows an exploded view of the various components of the tool device according to Figure 3 ; Figure 5 a molding device and an auxiliary mold part of the tool device according to Figure 4; Figure 6 shows two sectional views of the tool device during the production of a rim; Figure 7 shows a finished rim according to the application; Figure 8 shows sectional views of the tool device and the fiber layers of a rim during the implementation of the method according to the application; Figures 9-12 show various sectional views during the production of rims according to the application; and Figure 13 shows a schematic plan view of the ring device of the tool device according to Figure 3 .

[0082] In the Figures 1 and 2 A mountain bike and a racing bike 100 are shown, each equipped with rims 1 according to the application. The mountain bike and racing bike 100 each have a front wheel 101 and a rear wheel 102, each of which has rims 1 according to the application. The two wheels 101, 102 have spokes 109 for connecting the rim 1 to the hubs 110. Spoke holes 16 are provided on the rim 1 for this purpose.

[0083] A bicycle 100 has a frame 103, a handlebar 106, a saddle 107, a fork or suspension fork 104, and, in the case of a mountain bike, a rear wheel shock 105 may be provided. A crank 112 with pedals serves as the drive. Optionally, an electric auxiliary drive may be provided on the crank 112 and / or the wheels. The hub 110 of each wheel can be attached to the frame via a clamping system 49 (e.g., a thru-axle or a quick-release skewer).

[0084] Figure 3shows the tool device 50 in the assembled state with fiber layers already inserted for producing the rim 1, before the tool device 50 is inserted into a separate pressing device, in which the tool device 50 is also heated to accelerate the curing of the fiber composite material. The tool device 50 is essentially rotationally symmetrical about an axis of symmetry 11, which in any case forms an axis of symmetry for the finished rim 1.

[0085] Figure 4 shows an exploded view of the tool assembly 50, with a locking ring 90 shown at the top, which has a clamping section 91 and a screw not visible here. The locking ring 90 can be placed around the other components of the tool assembly 50 and can serve as a clamping ring. If necessary, this locking ring 90 can be omitted.

[0086] The lowest element is a forming device 51, which has a flank contact surface 52, which serves to form one of the two rim flanks of the rim 1 to be produced. Fastening means 56 and alignment units 57 are formed or arranged on the forming device 51, with which the forming device 51 is fastened to the ring device 80 and the other forming device 61 via corresponding fastening means 56 or to the alignment units 57. The ring device 80 comprises a ring unit 80a and in particular a ring coating 40a (cf. Fig. 6 ) and has alignment units 87.

[0087] The other molding device 61 also has alignment units 67. Both molding devices 51, 61 can each consist of a molding unit 51a, 61a (as core) and a molding cover 51b, 61b (cf. Figure 11 ).

[0088] As in Figure 4As can be seen, the ring unit 80a of the ring device 80 consists of several ring segments 81-83 that extend circumferentially around the central axis of symmetry 11. This allows the ring segments to be removed individually during removal.

[0089] Figure 5 shows a molding device 51 and the associated auxiliary mold part 70, which are connected to each other to cover the flank contact surface 72 and the rim base areas 54 and 74 with fiber layers of the fiber composite material. This reinforces the rim base area with a common continuous layer.

[0090] The molding device 61 and the auxiliary mold part 70 are connected to each other or placed on top of each other at the parting surfaces 55 and 75.

[0091] Figure 6shows two schematic representations of the tool device 50 with fiber layers 21-23 and 25 arranged therein. The tool device consists in the assembled state essentially of a first mold device 51, a second mold device 61 and the ring device 80, which in turn comprises a ring unit 80a with (in the circumferential direction) several ring segments 81-83 (cf. Figure 4 ) and (in the axial direction) ring segments 85, 86 and a ring coating 40a.

[0092] The ring coating 40a is made of a more elastic material than the ring unit 80a (core of 80) and the molding devices 51, 61 or their molding units 51a, 61a (cores of 51, 61). As a result, during curing in the tool device 50, the areas of the rim flanges are pressed on one side by a more elastic material (ring coating 40a) and on the other side by a less elastic material on the molding devices 51, 61 or the ring unit 80a. The heat generated during curing and the thermal expansion further increase the pressure. The ring coating 40a is made in particular of a rubber or rubber-like material, or preferably of a silicone or the like, or of a combination. The ring unit 80a and the molding devices 51, 61 are preferably made of metal, in particular light metal.

[0093] Here, the annular coating 40a also covers the area of the rim base 5, which is pressurized from the inside by the (inflatable) tube 32 during curing. The annular coating 40a counteracts this from the outside.

[0094] If necessary, the molding devices 51 and 61 can also be formed in multiple parts and, for example, additionally comprise mold units (mold cores) 51a and 61a. Preferably, however, the molding devices 51 and 61 are each formed in one piece, although separate mold coverings 51b, 61b can be provided if necessary (see FIG. Figure 11). The forming device 51 has a flank contact surface 52 for the left rim flank 2, while the right rim flank 3 is formed by a flank contact surface 62. Fiber layers 21 and 22 are applied to the flank contact surfaces 52 and 62, respectively. Reinforcing layers 25 are also applied in the area of the rim base 4. The rim base 5 is formed by at least one fiber layer 23, which is applied radially inward to the ring device 80.

[0095] The two in Figure 6The rims 1 shown each have rim flanges 6, 7, which are formed by fiber layers 21, 23, and 25. The outer surfaces 8 and 9 of the two rim flanks 2, 3, which are later visible from the outside, are each formed by the first fiber layer 21 placed on the flank contact surface 52, and by the first fiber layer 22 placed on the flank contact surface 62. The visible area of the rim base is formed by the first fiber layer 23, which was placed on the ring device 80. In the closed tool device, pressure is exerted on the rim flanges by the elastic ring covering 40a.

[0096] All visible surfaces or all visible layers of the finished rim 1 are thus provided by the fiber layers 21-23, which are each applied separately and over their entire surface to the forming devices 51 and 61, respectively, and the ring coating 40a of the ring device 80. This allows a particularly high surface quality to be achieved, since air inclusions or other defects can be better avoided than in the prior art.

[0097] In order to be able to exert pressure from the inside during curing, a hose 32 (shown only schematically) is regularly inserted, which can be led outwards via the later valve opening and which can be pressurised after the tool mold (tool device 50) has been closed in order to press the individual fibre layers 21-25 from the inside against the inner walls of the tool device 50. This ensures a reliable bond. The hose 32 can be elastic and expand when inflated. It is also possible and preferred for the hose 32 to be large enough or of a suitable size and, when inserted, to be placed over its entire surface on at least one flank contact surface and radially from the inside over its entire surface on the ring device.

[0098] If necessary, it is possible, as in the right part of Figure 6It can be seen that circumferential fiber strands or fiber bundles 29 are inserted in the intersection area of the rim flank 2, 3 and rim base 5 in order to reinforce the areas there and make them even more stable.

[0099] Figure 7 shows a schematic representation of a finished rim 1, which comprises a rim base 4, a rim well 5, and rim flanks 2, 3 with rim flanges 6, 7 formed thereon. A hollow chamber 10 can be seen inside. The rim 1 is manufactured from at least one fiber composite material using a method according to the application and a tool device according to the application. Figure 7 the minimum wall thickness 5a of the rim base 5 is also shown.

[0100] Figure 8shows two schematic representations of the production process. Each shows a highly schematic representation of the fiber layers in a tooling device 50, whereby the course and position of the fiber layers 21-23 and 25 are intentionally sketched roughly in order to clearly explain the course of the individual fiber layers. Here, in the right-hand illustration of Figure 8 It can be seen that the fiber layer 21 was placed not only on the flank contact surface 52 of the molding device 51, but also on the rim base region 74 of the auxiliary molding 70 in order to form a reinforcing section 21a in the region of the rim base contact surface 62 of the other molding device 61. This enables an overlap of the individual fiber layers from one rim flank to the other rim flank in the region of the rim base.

[0101] Schematically circumferential fiber strands 29 can be seen in the intersection area 15 of the rim flanges 6, 7 with the rim base 5 or the rim flanks 2, 3.

[0102] In the lower area, the parting surfaces 55 and 65 of the two forming devices 51 and 61 can be seen, at which the two forming devices 51 and 61 are joined together.

[0103] Figure 8 shows on the left a preliminary stage in the production of rim 1 shown further right. In Figure 8 The left figure shows the state after the selected molding device 51 has been connected to the auxiliary molding part 70 and fiber layers 21 and reinforcement layers 25 have been placed thereon and after the auxiliary molding part 70 has been removed and the ring device 80 with the ring unit 80a and the ring cover 40a has been placed on the selected molding device 51.

[0104] Then the Figure 8The layer structure can be seen on the left, wherein due to the inherent rigidity of the prepregs 30 used (as fiber layers 21-23 and 25), the protruding reinforcement section 21a and the corresponding protruding regions of the fiber layers 25 (essentially) retain their shape. Subsequently, the other forming device 61 can be placed on the (selected) forming device 51 and the ring device 80, resulting in an overall closed rim profile for the rim 1. In the area of the rim flange 7, the fiber layer 22 placed on the forming device 61 is pressed against the fiber layer 23 on the ring covering 40a of the ring device 80. In the area of the rim base, the fiber layer 22 is pressed against the reinforcement section 21. The tube 32, which is subsequently inflated inside the hollow chamber 10 of the rim 1, then reliably presses all layers together and outwards onto the forming devices 51 and 62 and the ring covering 40a of the ring device 80.

[0105] The optically particularly important outer surfaces of the finished rim are of high quality, since the respective outer fiber layers 21, 22 and 23, which form the visible layers of the finished rim 1, are each pressed over the entire surface and separately onto the corresponding contact surfaces (flank contact surfaces 52, 62 and rim well contact surface 84). The rim flanges 6, 7 are manufactured to a particularly high quality, since the ring coating 40a ensures appropriate pressure.

[0106] Figure 9 shows the state during the production of a rim 1 after a first fiber layer 21 has been placed on the rim contact surface 52 of the selected molding device 51 and the rim base area 74 of the auxiliary mold part 70. Furthermore, reinforcement layers 25 have been applied, which rest against the molding surface 14 of the rim base 4 and assume the corresponding shape. In the left part of Figure 9the parting surfaces 55 and 75 of the forming device 51 and the auxiliary forming part 70 are still in contact with one another.

[0107] In the radially outer region, it can be seen that in the region of the rim flange 6, the fiber layer 21 has been folded over and forms a folded and radially inwardly extending section 21b in order to reinforce the rim flange 6 there.

[0108] In a corresponding manner, the other forming device 61 is also equipped with fiber layers 22, whereby the fiber layer 22 extends only over the flank contact surface 62. However, there, too, a section 22b is folded over in the area of the rim flange 7.

[0109] Subsequently, the auxiliary mold part 70 is carefully removed and the other mold device 61 with the parting surface 65 is brought up to the parting surface 55 of the (selected) mold device 51 and both are fastened together there. However, this preferably takes place only after the ring device 80 (in Figure 9shown above) was placed on the selected forming device 51 (see e.g. Figure 10 ).

[0110] The ring unit 80a of the ring device 80 is equipped with a ring coating 40a (here made of a silicone material) in the contact areas with the rim 1 to be manufactured. The ring coating 40a can be formed as a single piece in the circumferential direction or consist of several segments. The elastic ring coating 40a reliably ensures sufficient pressing pressure.

[0111] A wall thickness 43 or thickness of the ring coating 40a is shown and corresponds approximately to the wall thickness 6a, 6b in the area of the rim flank 2, 3 or the rim flange 6, 7. The wall thickness 43 can also be only half as large as shown or can be 2 mm, 3 mm, 4 mm, or even 5 mm or 6 mm. It is essential that sufficient dimensional stability and reproducibility of the wall thicknesses and surface quality of the rims 1 are achieved. Generally speaking, the wall thickness 43 or thickness of a coating 40 is in the range of the (minimum or maximum) wall thickness of the rim.

[0112] In particular, the wall thickness 43 is in the range between 1 / 8 (or 1 / 10) and 8 times (or 10 times) the minimum wall thickness 5a of the rim base 5 and / or can preferably be between 0.1 mm and 10 mm. In particularly preferred embodiments, the thickness 43 is between 1 mm and 6 mm and particularly preferably, for example, 4 mm + / - 2 mm.

[0113] Figures 10 and 11 show different process steps in the production of a different rim with a different layer pattern, where Figure 10 The state is shown after fiber layers 21 and 25 have previously been applied to the rim contact surface 52 and the rim base region 74 of an auxiliary molded part, and the auxiliary molded part 70 has been removed again. The projecting section 21a later reinforces the rim base 4 in the region of the rim flank 3.

[0114] An (optional) mold coating 51b on the mold unit 51a is shown in dashed lines and vertically hatched. The mold coating 51b consists of a more elastic material than the mold unit 51a, e.g., a rubber-like material or silicone or the like. As a result, the mold coating 51b is (somewhat) compressible and can preferably reduce its thickness or wall thickness by a few percent during production. It is possible that such a mold coating 51b is provided only in the area of the rim flanges. The mold coating 51b can be provided alternatively or in addition to the ring coating 40a.

[0115] Figure 11 shows the next step in the production of rim 1 after Figure 10 , whereby the other forming device 61 was placed on the ring device 80 with the ring coating 40a and the selected forming device 51. The complete layer pattern shown here as an example can now be seen.

[0116] Here, too, it is optionally possible for the molding device 61 to comprise a molding unit 61a and a molding cover 61b. The molding cover 61b then provides the flank contact surface 62 in its entirety or in the area of the rim flange.

[0117] It is also possible for the molding device 61 to comprise a molding unit 61a and a molding cover 61b, and for the ring device 80 to lack a ring covering 40a. At least in the area of the rim flanges, pressure is applied to the rim flange via the more elastic molding cover. The counterpressure is then applied directly by the ring unit 80a. In this case, the ring device 80 can consist solely of the ring unit 80a.

[0118] Figure 12shows an intermediate step in the production of another rim 1, wherein in the left-hand area the fiber layers 21 and 25 are shown, which are placed on the selected forming device 51 and the rim base area 74 of the auxiliary mold part 70, while in the right-hand part of Figure 12 the fiber layer 22 and the other fiber layers are shown, which are placed on the flank contact surface 62 and the rim bottom area 64.

[0119] Depending on the design, two separate ring covers 41, 42 can be provided on the ring device 80 or the ring unit 80a, which are mounted separately in the area of the rim flanges 6, 7. Alternatively, a completely continuous ring cover 40a can be mounted, covering both rim flanges 6, 7. By (locally) varying the wall thickness of the ring cover 40a, the ring device 80 can also be used on rims of different widths. It is also possible to use three or more separate ring covers, e.g., ring covers 41 and 42 for the rim flanges and one ring cover 40a for the rim well.

[0120] Figure 13 finally shows a schematic plan view of the ring device 80, in which the three circumferentially arranged ring segments 81-83 can be seen.

[0121] In all designs, the various fiber layers can be placed on top of each other at different angles. For example, in one layer, the fibers (warp threads or weft threads of a fabric) can be aligned at 30°, 60°, or even 45° to the circumferential direction of the finished rim. In a layer arranged above, the corresponding fibers can be aligned at a different angle (e.g., another of the angles listed).

[0122] Also in the Figures 11 and 12 The wall thickness 43 or thickness 43 of a coating 40 (i.e., ring coating 40a or molded coating 51b or 61b) is between 1 / 10 and 10 times the minimum wall thickness 5a of the rim base and / or can be between 0.1 mm and 10 mm. Here, too, the thickness 43 is in particular between 1 mm and 6 mm, e.g., 4 mm + / - 2 mm.

[0123] Overall, the invention provides an advantageous method and an advantageous tooling device with which rims 1 can be produced that have a reproducible high quality. It is possible to achieve a high surface quality of the external visible surfaces without complex reworking. An additional application of a lacquer layer or varnish or the like is not necessary. This is made possible, among other things, by the fact that the external visible layers of all external surfaces can be pressed directly and immediately onto the corresponding mold surfaces of the tooling device.

[0124] The manufacturing process is simple, thus avoiding errors and reducing the scrap rate. List of reference symbols: 1 rim 54 Rim base area 2 rim flank 55 Separation surface 3 rim flank 56 Fasteners 4 Rim base 57 Alignment unit 5 Rim bed 61 Forming device 6 Rim flange 61a Forming unit 7 Rim flange 61b mold coating 8 visible area 62 flank contact surface 9 visible area 64 Rim base area 10 hollow chamber 65 Separation surface 11 axis of symmetry 67 Alignment unit 14 Forming surface rim base 70 Auxiliary molding 15 intersection area 74 Rim base area 16 spoke hole 75 Separation surface 20 Fiber composite material 77 Alignment unit 21 Fiber layer, visible layer 80 Ring device 21a Reinforcement section 80a Ring unit 21b folded section 80b Material from 80a 22 Fiber layer, visible layer 81-83 Ring segments 22b folded section 84 Rim well contact surface 23 Fiber layer, visible layer 85 Ring segments 24 Fiber layer 86 Ring segments 25 Reinforcement layer 87 Alignment unit 29 fiber strand 90 locking ring 30 Prepreg 91 clamping section 32 Hose 100 Bicycle 40 coating 101 wheel, front wheel 40a Ring coating 102 wheel, rear wheel 40b Material from 40a,51b,61b 103 Frame 41 Press ring 104 Fork, suspension fork 42 Press ring 105 rear wheel damper 43 thickness 106 handlebar 50 Tool setup 107 saddle 51 Forming device 109 spoke 51a Forming unit 110 hub 51b mold coating 112 crank 52 flank contact surface

Claims

1. Tool device (50) for manufacturing a rim (1) for at least partially muscle-powered vehicles and in particular bicycles (100), having opposite rim flanks (2, 3), a rim well (5) and a rim base (4), and rim flanges configured on the rim flanks (2, 3), comprising two molding devices (51, 61) and a circular device (80), wherein the molding devices (51, 61) each comprise contact surfaces (52, 62) for forming at least part of a rim flank (2, 3) and the external visible surface of the rim flanges, characterized in that the circular device (80) serves to form the rim well (5) and the axially inwardly oriented surfaces (8a, 9a) of the rim flanges (6, 7), wherein the circular device (80) comprises an annular unit (80a), and the molding devices (51, 61), one molding unit (51a, 61a) each, and wherein at least one of the units of an annular unit (80a) and molding units (51a, 61a) consists of a less elastic material (80b, 80c) and at least one coating (35, 40a, 80a) for attachment thereto, of a more elastic material (40b), and wherein the circular device (80) comprises an annular unit (80a) of a less elastic material (80b) and at least one ring coating (40a) of a more elastic material (40b), characterized in that the thickness (43) of the coating (40) is between 0.1 mm and 10 mm, and that the molding devices (51, 61) each comprise a molding unit (51a, 61a) of a less elastic material (80c) and at least one mold coating (51b, 61b) for attachment thereto, of a more elastic material (40b).

2. The tool device (50) according to claim 1, wherein the thickness (43) of the coating (40) is between 0.16 mm and 6 mm.

3. The tool device (50) according to any of the preceding claims, wherein in the radially inwardly region, the circular device (80) comprises a contact surface (84) for forming the rim well (5).

4. The tool device (50) according to the preceding claim, wherein the circular device (80) comprises two separate, axially spaced-apart pressing rings (41, 42), which match the inner outline of the rim flange (6, 7).

5. The tool device (50) according to any of the preceding claims, wherein the ratio of the coefficient of elasticity of the materials of the annular unit (80a) and of the ring coating (40a) is higher than 2 or 5, and / or wherein the ratio of the coefficient of elasticity of the materials of the molding unit (80a) and of the mold coating (40a) is higher than 2 or 5.

6. The tool device (50) according to any of the preceding claims, wherein the ring coating (40a) and the mold coating consist at least in part of a material taken from a group of materials comprising rubber-like materials and silicone materials.

7. The tool device (50) according to any of the preceding claims, wherein the thickness (43) of the ring coating (41, 42) and / or of the mold coating is more than 0.5 mm and / or less than 5 mm.

8. The tool device (50) according to any of the preceding claims, wherein the thickness (43) of the ring coating (41, 42) is greater than half the axial width (6a, 7a) of the rim flange (6, 7) and / or less than three times the axial width (6a, 7a) of the rim flange (6, 7).

9. The tool device (50) according to any of the preceding claims, wherein for manufacturing two rims (1) in different dimensions, the same annular unit (80a) may be employed by means of different ring coatings (40a).

10. Use of a tool device (50) for manufacturing a rim (1) for at least partially muscle-powered vehicles and in particular bicycles (100), wherein the tool device (50) is configured according to any of the preceding claims.