Wheel for a bicycle and composite spoke array for a bicycle wheel

Abstract

This invention relates to a bicycle wheel comprising a center hub, a rim, and a first spoke array removably attached to the center hub and the rim. The first spoke array is located on a first side of the wheel and includes a first center flange and a plurality of first spokes integral with and extending away from the first center flange, forming a first single component. The wheel includes a second spoke array removably attached to a radially inner portion of the center hub and the rim. The second spoke array is located on a second side of the wheel, opposite to the first side. The second spoke array includes a second center flange and a plurality of second spokes integral with and extending away from the second center flange, forming a second single component.

Description

[Technical Field]

[0001] This application claims the benefit of U.S. Provisional Patent Application No. 63,647,747, filed May 15, 2024, which is hereby incorporated by reference in its entirety.

[0002] Field of the Invention The present disclosure is generally related to a bicycle wheel, and more specifically, to a composite spoke array of a bicycle wheel. [Previous Technology]

[0003] Background of the Invention Conventional bicycle wheels may include a rim formed of extruded metal or other materials, which are bent and bonded into a circular shape with a uniform cross-section. Alloy spokes are attached to the hub and the rim.

[0004] Recently, other materials such as fiber-reinforced plastics have been used in the manufacture of bicycle rims. These materials can be formed into a circular shape through a non-extrusion process. For example, carbon fiber reinforced plastics can be used. [Summary of the Invention]

[0005] Summary of the Invention In one embodiment, a wheel for a bicycle includes a central hub having a first end and a second end opposite to the first end. The central hub is assembled for rotatable attachment to the bicycle. The wheel includes a rim and a first spoke array, the rim including a radially inner portion disposed along an inner circumference of the rim, the first spoke array being removably attached to the central hub and the radially inner portion of the rim. The first spoke array is located on a first side of the wheel and includes a first central flange and a plurality of first spokes integral with and extending away from the first central flange, such that they form a first single component. The wheel includes a second spoke array removably attached to the central hub and the radially inner portion of the rim. The second spoke array is located on a second side of the wheel. The second side of the wheel is opposite to the first side of the wheel. The second spoke array includes a second central flange and a plurality of second spokes, which are integral with the second central flange and extend away from the second central flange to form a second single component.

[0006] In one example, the center hub includes a first flange and a second flange. The first flange is closer to a first end of the center hub than to a second end of the center hub, and the second flange is closer to a second end of the center hub than to a first end of the center hub. The first spoke array is removably attached to the first flange of the center hub, and the second spoke array is removably attached to the second flange of the center hub.

[0007] In one example, the first central flange and the plurality of first spokes of the first spoke array are made of a first material, and the second central flange and the plurality of second spokes of the second spoke array are made of a second material.

[0008] In one example, the first material and the second material are the same carbon fiber composite material.

[0009] In one example, the wheel rim further includes a first sidewall and a second sidewall spaced apart from the first sidewall. The first sidewall and the second sidewall extend radially outward from the radially inner portion. The wheel rim further includes a radially outer tire engagement portion disposed along one outer circumference of the wheel rim. The radially outer tire engagement portion extends from the first sidewall and the second sidewall, respectively. The first sidewall, the second sidewall, the radially outer tire engagement portion, and the radially inner portion of the wheel rim are made of a third material. The third material is a carbon fiber composite material.

[0010] In one example, the first central flange is a first faceted annulus, and the second central flange is a second faceted annulus.

[0011] In one example, each of the first and second faceted rings has an inner surface shaped as a square, a pentagon, a hexagon, a heptagon, or an octagon.

[0012] In one example, the center hub further includes a first boss extending between the first flange and the first end, and a second boss extending between the second flange and the second end. One outer surface of the first boss has the same shape as the inner surface of the first small face ring, and one outer surface of the second boss has the same shape as the inner surface of the second small face ring.

[0013] In one example, the first boss includes a first retaining shape at the outer surface of the first boss, and the first facet ring includes a second retaining shape at the inner surface of the first facet ring. The second retaining shape is configured to interact with the first retaining shape such that the first spoke array is attached to the center hub. The second boss includes a third retaining shape at the outer surface of the second boss, and the second facet ring includes a fourth retaining shape at the inner surface of the second facet ring. The fourth retaining shape is configured to interact with the third retaining shape such that the second spoke array is attached to the center hub.

[0014] In one example, the first retaining shape is a first actuating shape extending into the first boss, and the second retaining shape is a second actuating shape extending away from the inner surface of the first small facet ring. The third retaining shape is a third actuating shape extending into the second boss, and the fourth retaining shape is a fourth actuating shape extending away from the inner surface of the second small facet ring.

[0015] In one example, the length of one of the plurality of first spokes extends between the first central flange and the rim. The length of one of the plurality of second spokes extends between the second central flange and the rim.

[0016] In one example, a spoke array can be removably attached to a central hub and a rim of a wheel for a bicycle, such that the spoke array forms all the spokes on one side of the wheel. The spoke array includes a central flange and a plurality of spokes integral with and extending away from the central flange, thereby forming a single component.

[0017] In one example, the central flange and the plurality of spokes integral with the central flange are made of a carbon fiber composite material. The carbon fiber composite material includes a polymer-based matrix and reinforcing fibers. The reinforcing fibers are carbon fibers.

[0018] In one example, one of the continuous fibers of the carbon fibers extends from one of the first spokes of the plurality of spokes to one of the second spokes of the plurality of spokes via the central flange.

[0019] In one example, the first spoke is at an angle relative to the second spoke.

[0020] In one instance, the angle is an acute angle.

[0021] In one example, the central flange is a small annular face with an inner surface shaped as a square, a pentagon, a hexagon, a heptagon, or an octagon.

[0022] In one example, the facet ring includes a shape-retaining body at one of the inner surfaces of the facet ring.

[0023] In one example, the shape-retaining body is a protrusion extending radially inward from the inner surface of the facet ring.

[0024] In one example, the protrusion is a circumferential rib extending around one of the inner surfaces of the facet ring.

[0025] In one example, a spoke assembly for a bicycle includes a center hub having a first end and a second end opposite to the first end. The center hub is configured for rotatable attachment to the bicycle. The spoke assembly includes a spoke array removably attached to the center hub, the spoke array being closer to the first end of the center hub than to the second end of the center hub. The spoke array includes a central flange and a plurality of spokes integral with and extending away from the central flange, thereby forming a single component.

[0026] In one example, the spoke array is a first spoke array, the central flange is a first central flange, the plurality of spokes are a first plurality of spokes, and the single component is a first single component. The spoke assembly further includes a second spoke array removably attached to one of the central hubs. The second spoke array includes a second central flange and a plurality of second spokes, the plurality of second spokes being integral with the second central flange and extending away from the second central flange to form a second single component.

[0027] In one example, the center hub includes a first flange and a second flange. The first flange is closer to the first end of the center hub than to the second end of the center hub, and the second flange is closer to the second end of the center hub than to the first end of the center hub.

Implementation Method

[0053] Detailed Description of Preferred Embodiments Carbon spokes are lighter than alloy spokes. However, attaching carbon spokes in a modular or replaceable manner to rims or hubs for bicycle wheels is challenging.

[0054] This disclosure provides examples of carbon composite spoke arrays and wheels including such spoke arrays. Carbon composite spoke arrays offer modularity and ease of replacement. For example, a bicycle wheel is provided comprising two composite spoke arrays forming spokes on opposite sides of the bicycle wheel. Each of the composite spoke arrays includes a composite spoke configured to structurally intersect a small faceted ring about the axis of rotation of the bicycle wheel hub. The composite spokes can be fastened to the rim in various ways, including, for example, with a threaded interface to a joint fixed in the rim.

[0055] The facet ring of the composite spoke array interfaces with the hub, allowing the spoke array to be removed and replaced using standard tools. The facet ring may at least partially form a continuation of the body of the composite spokes, the continuation being shaped to interface with the hub. The interface between the facet ring and the hub resists the torque transmitted between the hub and the spoke array.

[0056] These embodiments address or improve upon one or more of the disadvantages and / or other disadvantages mentioned above. The disclosed spoke array, for example, provides modularity and ease of repair. Furthermore, the disclosed spoke array can be lighter than a corresponding number of alloy spokes. The disclosed spoke array allows spoke preload force to be transferred across the hub without relying on the hub material to support the preload force, which allows for weight reduction of the wheel. The disclosed spoke array forms all spokes on one side of the wheel, thereby reducing wheel assembly time and reducing wheel complexity.

[0057] Turning now to the accompanying drawings, FIG1 generally illustrates a bicycle 50 employing wheels constructed according to the teachings of this disclosure. The bicycle 50 includes a frame 52, a front wheel 54 and a rear wheel 56 rotatably attached to the frame 52, and a drivetrain 58. A front brake 60 is provided for braking the front wheel 54, and a rear brake 62 is provided for braking the rear wheel 56. The bicycle 50 also typically has a seat 64 located near the rear end of the frame 52 and supported on an end of a seatpost 66 connected to the frame 52. The bicycle 50 also has handlebars 68 located near the front end of the frame 52. A brake lever 70 is supported on the handlebars 68 for actuating the front brake 60, the rear brake 62, or both the front brake 60 and the rear brake 62. If the brake lever 70 actuates only one of the front brake 60 and the rear brake 62, a second brake lever (not shown) may also be provided to actuate the other brake. The forward and / or forward riding direction or orientation of bicycle 50 is indicated by the direction of arrow A in Figure 1. Therefore, the forward direction of bicycle 50 is indicated by the direction of arrow A. Although the bicycle 50 depicted in Figure 1 is a road bicycle with drop-style handlebars 68, this disclosure is applicable to any type of bicycle, including mountain bikes with full or partial suspension.

[0058] The drivetrain 58 includes a chain C and a front sprocket assembly 72, which is coaxially mounted with a crank assembly 74 having pedals 76. The drivetrain 58 also includes a rear sprocket assembly 78 coaxially mounted with the rear wheel 56, and a rear gear shifting mechanism, such as a rear derailleur 80.

[0059] As illustrated in Figure 1, the front sprocket assembly 72 may include one or more coaxially mounted chain links, gears, or sprockets. In this example, the front sprocket assembly 72 has at least one sprocket F (e.g., a chainring). The sprocket F has teeth 82 arranged around its respective circumference. As shown in Figure 1, the rear sprocket assembly 78 may include a plurality of coaxially mounted gears, inserts, or sprockets G. Each sprocket G1 to G11 also has teeth 84 arranged around its respective circumference. The number of teeth 84 on the rear sprockets G1 to G11 may gradually decrease from the largest diameter rear sprocket G1 to the smallest diameter sprocket G11. Although not described in detail herein, the front gear changer 85 may be operated to move from a first operating position to a second operating position to move the chain C between the front sprockets F. Similarly, the rear derailleur 80 may be operated to move between different operating positions to switch the chain C to one of the selected rear sprockets G1 to G11. In one embodiment, the rear sprocket assembly 78 may have more or fewer sprockets G. For example, in one embodiment, the rear sprocket assembly 78 may have twelve or thirteen sprockets. The size and configuration of the rear derailleur 80 can be modified to accommodate a particular plurality of sprockets. For example, the angles and lengths of the linkage assembly and / or the configuration of the cage of the rear derailleur 80 can be modified to accommodate a particular sprocket combination.

[0060] The rear derailleur 80 is depicted as a wireless, electrically actuated rear derailleur that is mounted or can be mounted to the frame 52 or frame attachment of the bicycle 50. The electric rear derailleur 80 has a base member 86 (e.g., a B-type knuckle) mounted to the bicycle frame 52. A linkage 88 has two links L that are pivotally connected to the base member 86 at a connection point of the base member linkage 88. A movable member 90 (e.g., a P-type knuckle) is connected to the linkage 88 at a connection point of the movable member linkage 88. A chain guide assembly 92 (e.g., a cage) is configured to engage the chain and maintain chain tension and has one or more cage plates 93 that have proximal ends pivotally connected to a portion of the movable member 90. The cage plates 93 are rotatable or pivotable about a cage rotation axis in the damping direction and the chain tension direction. Other gear conversion systems, such as mechanical or hydraulic control and / or actuation systems, may also be used.

[0061] The motor module may be carried together with the battery on the electric rear derailleur 80. The battery supplies power to the motor module. In one example, the motor module is located in the movable member 90. However, the motor module may alternatively be located elsewhere, such as in one of the links L of the linkage 88 or in the base member 86. The motor module may include a gear mechanism or a shifting device. As known in the art, the motor module and gear mechanism may be coupled to the linkage 88 to laterally move the cage plate 93, and thus switch the chain C in the rear sprockets (e.g., G1 to G11) on the rear sprocket assembly 78.

[0062] The cage plate 93 also has a distal end that carries a tensioner tooth or wheel. This wheel also has teeth around its circumference. The cage plate 93 is biased in the chain tensioning direction to maintain the tension of the chain C. The chain guide assembly 92 may also include a second tooth or wheel, such as a guide wheel positioned closer to the proximal end of the cage plate 93 and the movable member 90. In operation, the chain C is routed around one of the rear sprockets (e.g., G1 to G11). The upper section of the chain C extends forward to the front sprocket assembly 72 and is routed around a front sprocket F. The lower section of the chain C returns from the front sprocket assembly 72 to the tensioner wheel and is then routed forward to the guide wheel. The guide wheel guides the chain C to the rear sprockets (e.g., G1 to G11). The lateral movement of the cage plate 93, tensioner wheel and guide wheel determines the lateral position of chain C to align with one of the selected rear sprockets (e.g. G1 to G11).

[0063] The bicycle 50 may include one or more bicycle control devices mounted to the handlebars 68. The bicycle control device may include one or more types of bicycle control and / or actuation systems. For example, the bicycle control device may include a brake actuation system for controlling the front brake 60 and / or the rear brake 62, and / or a gear shifting system for controlling the drivetrain 58. Other control systems may also be included. For example, in some embodiments, the system may be applied to bicycles using only a front gear shifter or only a rear gear shifter. Furthermore, one or more bicycle control devices may also include suspension, seatpost, and / or other control systems for the bicycle 50.

[0064] The front wheel 54 and / or rear wheel 56 of the bicycle 50 may include a tire 120 attached to a radially outer tire engagement portion of the rim 122. The tire 120 may have any number of sizes. For example, the tire 120 may have a width greater than 34 mm. As shown in Figures 1 and 2, a plurality of spokes 124 are directly attached to the rim 122 (e.g., via a threaded interface with a metal connector fixed in the rim 122). Alternatively, the spokes 124 may be attached and / or fastened to the rim 122 using other structural components. The spokes 124 extend from the rim 122 and are attached to the center hub 126. The spokes 124 maintain tension between the rim 122 and the center hub 126 to provide operational stiffness to the individual wheels 54, 56 for use on the bicycle 50. The center hub 126 is assembled for rotatable attachment to the bicycle frame 52.

[0065] Figure 2 illustrates a bicycle wheel having a rim 122, spokes 124, and a center hub 126, such as the wheel 54 in Figure 1, which is removed from the rest of the bicycle 50 and without a tire attached. The rim 122 includes a tire engagement portion 130 for engaging with a tire 120, as shown in Figure 1. The tire engagement portion 130 is configured radially externally to a spoke receiving surface 132 disposed along the inner circumference 134 of the rim 122. In other words, the tire engagement portion 130 is a radially external tire engagement portion. In one embodiment, the tire engagement portion 130 is disposed along the outer circumference 135 of the rim 122. The tire engagement portion 130 is configured for attachment to a tubeless tire. Other configurations of the tire engagement portion 130 may be provided for clamp-type tire attachment configurations, including beaded interlock attachments. Other configurations of the tire engagement portion 130 may also be provided to allow the use of other types of tires on the rim 122. For example, tubeless tires, including those with interlocking bead attachments, may be used.

[0066] The rim 122 has a structure at its receiving portion near the spoke receiving surface 132 for attaching the spokes 124 to the rim 122. Thus, the spoke receiving surface 132 is part of the spoke engagement portion 136 (e.g., a radially inner portion) of the rim 122. In one embodiment, the spoke engagement portion 136 of the rim 122 is disposed along the inner circumference 134 of the rim 122. In another embodiment, the spoke receiving surface 132 and the spoke engagement portion 136 may be separate components and / or portions of the rim 122. For example, the spokes 124 may pass through the spoke receiving surface 132, and the structure for attaching to the rim 122 may be positioned near the tire engagement portion 130.

[0067] In embodiment 1000 of Figures 19 and 20, the spoke engagement portion 136 of the rim 122 includes a spoke receiving surface 132 having a rim-to-spoke interface 1003. Spokes 124 are received within a spoke interfacing structure 1001 of the spoke-rim-to-spoke interface 1003. The spoke interfacing structure 1001 is at least partially located within the rim 122. The spoke interfacing structure 1001 is at least partially located at the inner circumference 134 of the rim 122. The spoke interfacing structure 1001 is at least partially located inside the rim 122 at the spoke receiving surface 132. The spoke interfacing structure 1001 is at least partially located outside the rim 122 at the spoke receiving surface 132.

[0068] In the example of FIG. 20, the spoke interface structure 1001 includes a spoke joint 1002. In this example, the spoke joint 1002 rests inside the rim 122 at the spoke receiving surface 132. The spoke interface structure 1001 includes a spoke engagement structure 1004. In this example, the spoke engagement structure 1004 has a first end that interfaces with or connects to the spoke joint 1002. The spoke engagement structure 1004 has a second end that receives spokes 124. When the bicycle wheel is assembled, at least a portion of the spoke engagement structure 1004 passes through the spoke hole 1020 of the rim 122, such that the spoke joint 1002 is inside the rim 122 and the second end of the spoke engagement structure 1004 is outside the rim.

[0069] As shown in Figure 21, the second end of the spoke engagement structure 1004 includes an opening 1012. The opening 1012 allows the spoke 124 to enter the cavity 1010, which is sized and shaped to receive the end 1014 of the spoke 124. In the example of Figure 21, at least some adhesive 1008 secures the end 1014 of the spoke 124 to the spoke engagement structure 1004. At least some adhesive 1008 is present between the inner surface of the cavity 1010 and the end 1014 of the spoke 124 to secure the spoke 124 within the cavity 1010.

[0070] In one embodiment, the adhesive may be any type of adhesive capable of securing the end 1014 of the spoke 124 to the cavity 1010. For example, adhesives such as glue, tape, natural oils, and liquid adhesives may be used.

[0071] Figure 22 shows an alternative embodiment 2000 of the spoke engagement structure 2001. In the embodiment of Figure 22, the spoke engagement structure 2004 includes an opening 2012 for the spoke 2224 to travel into a cavity 2010. The inner surface of the cavity 2010 includes threads 2006. The threads 2006 of the cavity 2010 thread-engage with threads 2008 at the end 2014 of the spoke 2224. The spoke 2224 is screwed into the spoke engagement structure 2004 to secure the spoke 2224 to a bicycle rim, such as rim 122.

[0072] In an alternative embodiment 3000 of the spoke interface structure 3001 shown in FIG. 23, the spoke interface structure 3004 is shorter in length than the spoke interface structure 2004 shown in FIG. 22. The spoke interface structure 3001 includes a tension adjustment element 3008 at a second end of the spoke interface structure 3004. The tension adjustment element 3008 includes an opening 3012 for receiving the spoke 2224. The tension adjustment element 3008 is threadedly engaged with a thread 2008 at an end 2014 of the spoke 2224. When rotated, the tension adjustment element 3008 can adjust the tension of the spoke 2224.

[0073] The tension adjusting element 3008 may be a hexagonal nut or other structure. In one embodiment, the tension adjusting element 3008 may be integrated with the spoke engagement structure 3004 as a single piece. In an alternative embodiment, the tension adjusting element 3008 may be a separate piece from the spoke engagement structure 3004.

[0074] As shown in Figure 24, one alternative embodiment 4000 of the spoke interface structure 4001 is shown. The difference between the spoke interface structure 4001 and the spoke interface structure 3001 is that the tension adjustment element 4008 is located at the top of the spoke joint 4002, rather than at the second end of the spoke joint structure 2004.

[0075] The tension adjusting element 4008 may be a hexagonal nut or other structure. In one embodiment, the tension adjusting element 4008 may be integrated with the spoke joint 4002 as a single piece. In an alternative embodiment, the tension adjusting element 4008 may be a separate piece from the spoke joint 4002.

[0076] In one embodiment, tension adjusting elements 3008 and / or 4008 can be configured to rotate individually or in combination with the rest of the spoke interface structure 3001 and / or 4001 to adjust spoke tension. In one embodiment, a tool can be used to rotate tension adjusting elements 3008 and / or 4008. In an alternative embodiment, tension adjusting elements 3008 and / or 4008 can be rotated without tools. Tension adjusting elements 3008 and / or 4008 may include a tool interface. In FIG2, rim 122 includes a first sidewall 138 and a second sidewall extending between tire engagement portion 130 and spoke engagement portion 136. For example, the first sidewall 138 and the second sidewall extend radially outward from spoke engagement portion 136 to tire engagement portion 130. The first sidewall 138 and the second sidewall are spaced apart.

[0077] The rim 122 may be made of any number of materials. For example, the rim 122 may be made of a metal (e.g., aluminum or aluminum alloy). In one embodiment, at least a portion of the rim 122 (e.g., the spoke joint portion 136 and / or the tire joint portion 130) is formed of one or more composite materials (e.g., carbon fiber composite materials). In one embodiment, the entire rim 122 is formed of two or more composite materials. Other combinations may also be provided. For example, a combination of a first composite material and a second composite material forms an integral rim comprising a layer of the first composite material and a layer of the second composite material, including the tire joint portion 130, a first sidewall 138, a second sidewall, and the spoke joint portion 136.

[0078] The front wheel 54 and the rear wheel 56 may include rims 122 that are configured for use with wheels of any size. In one embodiment, the rims 122 are configured for use with wheels conforming to wheel standards.

[0079] The front wheel 54 and the rear wheel 56 can rotate about the central hub 126 in either direction. For example, as shown in FIG2, the front wheel 54 and the rear wheel 56 can be configured to rotate about the central hub 126 in a specific rotational direction. In another example, the front wheel 54 and the rear wheel 56 can be configured to rotate in the opposite direction to the specific rotational direction.

[0080] In the manufacturing process, for each of the rims 122 (e.g., the front wheel 54 and the rear wheel 56), a layer of at least one composite material forming the first sidewall 138 and the second sidewall may be integrated with a layer of one or more composite materials forming the spoke joint portion 136 and the tire joint portion 130 of each wheel 54, 56. Then, a curing process may be used, for example, to form an integral, one-piece rim 122. The rims 122 of the front wheel 54 and the rear wheel 56 may be formed using other manufacturing processes.

[0081] Referring to FIG. 2, the plurality of spokes 124 include a first spoke 124a at a first side 160 of each wheel 54, 56, and a second spoke 124b at a second side 162 of each wheel 54, 56. The first spoke 124a together with a first flange 164 (e.g., a first small face ring) forms a first spoke array 166, and the second spoke 124b together with a second flange 168 (e.g., a second small face ring) forms a second spoke array 170. The first spoke array 166 and the second spoke array 170 are each a single component. The first spoke array 166 and the second spoke array 170 are removably attached to the central hub 126 at or adjacent to opposite sides of the central hub.

[0082] Figures 3 and 4 illustrate one embodiment of the wheel rim 200. In one embodiment, a lamination pattern for the composite material layer for the wheel rim is provided prior to a curing process, for example, to form the wheel rim 200. After the curing process, the composite material layer may be part of a monolithic, one-piece wheel rim 200. The resulting monolithic, one-piece wheel rim 200 may be formed from a composite laminate comprising one or more composite materials or multiple compressed layers. In another embodiment, the wheel rim 200 is at least partially made of a metal such as aluminum or an aluminum alloy. In other embodiments, the wheel rim 200 may be made of different, additional, and / or fewer materials.

[0083] The composite laminate may include any number of composite materials. For example, one or more composite materials in the composite laminate may include a first composite material, a second composite material, a third composite material, or any combination thereof. The composite laminate may include more or fewer composite materials. For example, the composite laminate may include only the first composite material and the second composite material, or it may include only the second composite material and the third composite material. In one embodiment, the composite laminate may include only the first composite material, only the second composite material, or only the third composite material.

[0084] The first composite material may include a polymer-based matrix (e.g., a first polymer-based material) and reinforcing fiber (e.g., a first reinforcing material). The first polymer-based material may be any number of materials, including, for example, plastics, acrylics, resins, epoxy resins, or any combination thereof, and the second reinforcing fiber may be any number of materials, including, for example, carbon. Other polymer-based materials and / or other reinforcing fibers may be used.

[0085] The second composite material may include a polymer-based matrix (e.g., a second polymer-based material) and reinforcing fiber (e.g., a second reinforcing material). The second polymer-based material may be any number of materials, including, for example, plastics, acrylics, resins, epoxy resins, or any combination thereof, and the second reinforcing fiber may be any number of materials, including, for example, glass fiber. Other polymer-based materials and / or other reinforcing fibers may be used.

[0086] The third composite material may include a polymer-based matrix (e.g., a third polymer-based material) and reinforcing fiber (e.g., a third reinforcing material). The third polymer-based material may be any number of materials, including, for example, plastics, acrylics, resins, epoxy resins, or any combination thereof, and the fiber of the third reinforcing material may be any number of materials, including, for example, natural fibers. For example, the fiber of the third reinforcing material may be flax fiber, kenaf fiber, hemp fiber, jute fiber, or jute fiber. Other polymer-based materials and / or other reinforcing fibers may be used.

[0087] The rim 200 includes a radially outer tire engagement portion 202 (e.g., disposed along the outer circumference of the rim 200), a radially inner portion 204 (e.g., a spoke engagement portion), a first sidewall 206, and a second sidewall 208 spaced apart from the first sidewall 206. The first sidewall 206 and the second sidewall 208 extend radially outward from the radially inner portion 204 to the radially outer tire engagement portion 202. The radially outer tire engagement portion 202 extends from the first sidewall 206 and the second sidewall 208, respectively.

[0088] The radially outer tire engagement portion 202 of the rim 200 includes a first tire holding portion 210 and a second tire holding portion 212 spaced apart from the first tire holding portion 210. The first tire holding portion 210 extends from a first sidewall 206, and the second tire holding portion 212 extends from a second sidewall 208.

[0089] The first tire retaining portion 210 includes a first tire retaining wall 214. In an alternative embodiment, the first tire retaining portion 210 also includes a first protrusion (e.g., a first tire retaining morphology) (not shown). The first protrusion may extend away from the first tire retaining wall 214. The first protrusion may be any number of shapes, including, for example, a shape having a rectangular cross-section with a semi-circular cap. The first protrusion may extend circumferentially around the rim 200. The second tire retaining portion 212 includes a second tire retaining wall 216. The second tire retaining wall 216 is opposite to and spaced apart from the first tire retaining wall 214. In an alternative embodiment, the second tire retaining portion 212 also includes a second protrusion (e.g., a second tire retaining morphology) (not shown). The second protrusion may extend away from the second tire retaining wall 216 toward the first tire retaining portion 210. The second protrusion may be any number of shapes, including, for example, a shape having a rectangular cross-section with a semi-circular cap. The second protrusion may extend circumferentially around the rim 200. The first and second protrusions may be other shapes.

[0090] The rim 200 may house a tire 120 (see Figure 1), such as a tubeless tire. The tire 120 may include a bead that interacts with radially outer tire engagement portions 202 of the rim 200 (e.g., a first tire holding portion 210 and a second tire holding portion 212) to attach and retain the tire 120 to the rim 200. The bead may include any number of materials, such as steel wire or aramid (e.g., Kevlar™) fibers, to prevent the tire 120 from detaching from the rim 200. For example, the bead is able to resist stretching from internal air pressure due to reinforcement with steel wire or Kevlar™ fibers. Alternatively, the bead may be made of the same material as the tire 120 (e.g., rubber).

[0091] The radially outer tire engagement portion 202 also includes a groove 218 located between the first tire holding portion 210 and the second tire holding portion 212 of the rim 200. The groove 218 provides a volume in which the tire bead of the tire 120 can be placed when the tire 120 is attached to the rim 200. When the tire 120 is inflated, the tire beads of the tire 120 move away from each other until the tire beads interact with the first tire holding portion 210 and the second tire holding portion 212, respectively. When inflated, the tire beads of the tire 120 abut against the first tire holding wall 214 and the second tire holding wall 216, respectively. In one embodiment, the first tire holding shape and the second tire holding shape, for example, hold the tire bead of the tire 120 within the radially outer tire engagement portion 202 (e.g., hold the tire bead of the tire 120 engaged with the first tire holding wall 214 and the second tire holding wall 216), and thus prevent the tire 120 from detaching from the rim 200. The contact between the tire bead and the first tire retaining wall 214 and the second tire retaining wall 216 respectively forms a seal between the inflated tire 120 and the rim 200.

[0092] The radially outer tire engagement portion 202 may also include ridges (e.g., bead protrusions; first bead protrusion and second bead protrusion) on opposite sides of the groove 218. A first frame 220 (e.g., a first bead frame) extends away from the first tire retaining wall 214 (between the first tire retaining wall 214 and the first bead protrusion), and a second frame 222 (e.g., a second bead frame) extends away from the second tire retaining wall 216 (between the second tire retaining wall 216 and the second bead protrusion). In one embodiment, a curved transition region 224 extends between the first frame 220 and the first tire retaining wall 214, and between the second frame 222 and the second tire retaining wall 216, respectively. The bead protrusions may be positioned on opposite sides of the groove 218 and may protrude relative to the first frame 220 and the second frame 222, respectively. If the tire 120 loses pressure, the bead protrusions may help hold the tire 120 on the rim 200.

[0093] In one embodiment, a layer of one or more composite materials (e.g., a first composite material, a second composite material, and / or a third composite material) is formed into a strip. The strip of one of the composite materials (e.g., the first composite material) may include fibers extending along a finite length of the strip. In one embodiment, the fibers extend in the principal strength direction of the strip (e.g., along the length of the strip). For example, the strip has a unidirectional fiber orientation along the length of the strip. In another embodiment, some of the fibers do not extend in the principal strength direction (e.g., less than 20% of the fibers, less than 10% of the fibers, or less than 5% of the fibers).

[0094] The strips can be any number of shapes and / or sizes. For example, the strip shape is rectangular. Other shapes, such as square strips and non-rectangular parallelogram strips, can be provided. The width of the strip is perpendicular to its length. The length of the strip can be defined by, for example, the size of the radially outer tire engagement portion 202, the first sidewall 206, the second sidewall 208, and / or the radially inner portion 204 of the rim 200. In other words, the length of the strip can be at least as high or as wide as the radially outer tire engagement portion 202, the first sidewall 206, the second sidewall 208, and / or the radially inner portion 204 of the rim 200. In one embodiment, the strip width is between 10 mm and 50 mm. For example, the strip width is 30 mm. In other embodiments, the strip is wider or narrower (e.g., 60 mm). A smaller strip width allows for better optimization of fiber orientation, but at the cost of increased manufacturing complexity. In one embodiment, the strip width is the same as the radial width of the rim 200.

[0095] Layers of different shapes, greater widths, and / or greater lengths may be used. For example, at least some of the layers of the first composite material may extend a quarter, half, or all of the way around the rim 200. Layers of the first composite material of different sizes and / or shapes may be used, depending on the application within the rim 200 (e.g., forming an outer surface, providing strength and rigidity at high load locations within the rim).

[0096] The layers of one or more composite materials may have any number of thicknesses. For example, the thickness of the layers of one or more composite materials may be 0.4 mm or less (e.g., 0.25 mm or less). Other thicknesses of the layers of one or more composite materials may be provided.

[0097] For example, for one or more components of the wheel rim 200, each of the several layers of one or more composite materials (e.g., a second composite material) may be unidirectional. The several layers of the composite material may be stacked and stitched together, forming a mesh or random pattern within the layers. In other words, at least some of the several layers of the composite material are unidirectional in different directions. The thickness of such layers may be 1.2 mm or more. Other thicknesses are available.

[0098] Figures 5 to 12 illustrate a first embodiment of a spoke array 300, which can be removably attached to the center hub (e.g., center hub 126) of a wheel (e.g., front wheel 54 or rear wheel 56) of a bicycle (e.g., bicycle 50). The spoke array 300 forms all spokes on one side of the bicycle wheel (e.g., first side 160 or second side 162). The spoke array 300 includes a center flange 302 and a plurality of spokes 304, which are integral with the center flange 302 and extend away from the center flange, thus forming a single component.

[0099] The plurality of spokes 304 may include any number of spokes 304. For example, as shown in Figures 5 to 12, the plurality of spokes 304 may include ten spokes integral with and extending away from the central flange 302. In other embodiments, the plurality of spokes 304 may include more or fewer spokes 304.

[0100] The plurality of spokes 304 and the central flange 302 may be made of any number of materials (e.g., one or more materials). The one or more materials may include a first composite material. In one embodiment, the one or more materials may alternatively or additionally include a second composite material, a third composite material, and / or one or more other materials (e.g., metals, such as alloys).

[0101] In one embodiment, a plurality of spokes 304 and a central flange 302 are made of the same material (e.g., a first composite material). In another embodiment, a plurality of spokes 304 and a central flange 302 are made of different materials (e.g., a first composite material and a second composite material, respectively). In yet another embodiment, a subset of the spokes among the plurality of spokes 304 are made of different materials.

[0102] Each of the plurality of spokes 304 extends away from the central flange 302. The plurality of spokes 304 may be curved or straight. In one embodiment, a first portion of the spokes of the plurality of spokes 304 is curved, and a second portion of the spokes of the plurality of spokes 304 is straight. The length L of each spoke of the plurality of spokes 304 is defined by the distance along the individual spoke extending away from the central flange 302 to the end 306 of the individual spoke 304. In one embodiment, all spokes of the plurality of spokes 304 have the same length L. In another embodiment, at least some spokes of the plurality of spokes 304 have different lengths L.

[0103] The central flange 302 may be, for example, any number of small rings of different shapes. The small ring 302 may have one or more inner surfaces 308, one or more outer surfaces 310, a first side 312 (e.g., the top side) and a second side 314 (e.g., the bottom side) opposite to the first side 312.

[0104] For example, referring to FIG7, the facet ring 302 may be formed as a pentagon and thus have five inner surfaces 308 (e.g., with rounded transition portions 315 between adjacent inner surfaces in the five inner surfaces 308) and five outer surfaces 310. As discussed below, facet rings 302 of different shapes may be provided.

[0105] The first embodiment of the spoke array 300 in Figures 6 to 11 illustrates an example of a spoke pattern 316. Within the spoke pattern 316, spoke pairs of a plurality of spokes 304 intersect, such that the five outer surfaces 310 respectively form triangles 318 (e.g., five triangles). The triangles 318 formed by the spoke pairs 316 combine with small facets 302 shaped as pentagons to form a star shape. This spoke pattern 316 can provide strength to the wheel. In other embodiments, other spoke patterns may be provided.

[0106] Referring to Figures 5 and 9 to 12, the center hub 126 has a first end 320 and a second end 322 opposite to the first end 320. The center hub 126 includes a first flange 324 adjacent to the first end 320 of the center hub 126 (e.g., closer to the first end 320 of the center hub 126 than to the second end 322 of the center hub 126), and a second flange 326 adjacent to the second end 322 of the center hub 126 (e.g., closer to the second end 322 of the center hub 126 than to the first end 320 of the center hub 126). The center hub 126 also includes a first boss 328 extending away from the first flange 324 between the first flange 324 and the first end 320 of the center hub 126, and a second boss 330 extending away from the second flange 326 between the second flange 326 and the second end 322 of the center hub 126.

[0107] The size and shape of the first boss 328 (e.g., its outer periphery) may correspond to the size and shape defined by one or more inner surfaces 308 of the small facet ring 302 of the spoke array 300. For example, the first boss 328 may include one or more outer surfaces 332 (e.g., five outer surfaces 332 having rounded transition portions 334 between adjacent outer surfaces of five outer surfaces 332). For example, the five outer surfaces 332 of the first boss 328 may be sized and the outer periphery of the first boss 328 may be shaped such that when the small facet ring 302 is positioned around the first boss 328 and positioned on the first flange 324, the five outer surfaces 332 of the first boss 328, for example, respectively contact (e.g., abut) the five inner surfaces 308 of the small facet ring 302. The first boss 328 may have any number of different heights. For example, the height of the first boss 328 may be greater than or equal to the thickness of the small facet ring 302. Other sizes and / or shapes of the first boss 328 may be provided.

[0108] The size and shape of the second boss 330 (e.g., its outer periphery) may correspond to the size and shape defined by one or more inner surfaces 308 of the small facet ring 302 of the spoke array 300. For example, the second boss 330 may include one or more outer surfaces 336 (e.g., five outer surfaces 336 having rounded transition portions 338 between adjacent outer surfaces of five outer surfaces 336). For example, the five outer surfaces 336 may be sized and the outer periphery of the second boss 330 may be shaped such that when the small facet ring 302 is positioned about the second boss 328 and positioned on the second flange 326, the five outer surfaces 336 of the second boss 330, for example, respectively contact the five inner surfaces 308 of the small facet ring 302. The second boss 330 may have any number of different heights. For example, the height of the second boss 330 may be greater than or equal to the thickness of the small facet ring 302. Other sizes and / or shapes of the second boss 330 may be provided.

[0109] The center hub 126 may include one or more first retaining features 340 (e.g., first retaining features 340) at the first boss 328 and / or the first flange 324. In one embodiment, the first retaining feature 340 is a first actuating feature. In one embodiment, the first actuating feature 340 extends into the first boss 328 of the center hub 126. For example, the first actuating feature 340 is a first groove extending at least partially around the periphery of the first boss 328. In one embodiment, the first groove 340 extends completely around the periphery of the first boss 328 (e.g., disposed within all the outer surfaces of one or more outer surfaces 332 of the first boss 328). In another embodiment, the first actuating feature 340 is a protrusion that extends at least partially around the periphery of the first boss 328 and away from one or more outer surfaces 332 of the first boss 328.

[0110] The center hub 126 may also include one or more second retaining features (e.g., a second retaining feature; not shown) at the second boss 330 and / or the second flange 326. In one embodiment, the second retaining feature is a second actuating feature. In one embodiment, the second actuating feature extends into the second boss 330 of the center hub 126. For example, the second actuating feature is a second groove that extends at least partially around the periphery of the second boss 330. In one embodiment, the second groove extends completely around the periphery of the second boss 330 (e.g., disposed within all outer surfaces of one or more outer surfaces 336 of the second boss 330). In another embodiment, the second actuating feature is a protrusion that extends at least partially around the periphery of the second boss 330 and away from one or more outer surfaces 336 of the second boss 330.

[0111] In other embodiments, the center hub 126 may include more and / or different retaining features at the first boss 328 and / or the second boss 330. For example, the center hub 126 may include two or more first retaining features 340 at the first boss 328 of the center hub 126, and / or may include two or more second retaining features at the second boss 330 of the center hub 126. For example, the first boss 328 includes two recesses 340 spaced apart from each other within the first boss 328, and the second boss 330 includes two recesses spaced apart from each other within the second boss 330.

[0112] Referring to Figures 10 and 11, the small facet ring 302 of the spoke array 300 includes one or more retaining features 342 (e.g., retaining features). For example, the small facet ring 302 of the spoke array 300 includes retaining features 342 at one or more inner surfaces 308 of the small facet ring 302. In one embodiment, the retaining features 342 is a tactile feature that extends at least partially around an inner periphery defined by one or more inner surfaces 308 of the small facet ring 302 away from the inner surfaces 308. For example, the tactile feature 342 extends completely around the inner periphery of the small facet ring 302. The tactile features 342 can be arranged in any number of ways. For example, the tactile feature 342 may be a protrusion or rib extending completely around the inner circumference of the small facet ring 302.

[0113] The actuating morphology 342 can be sized and / or shaped in any number of ways. For example, the actuating morphology 342 is sized and shaped to correspond to the first retaining morphology 340 of the first boss 328 and / or the second retaining morphology of the second boss 330. In other words, for example, when the spoke array 300 is positioned on the first boss 328 or the second boss 330 of the center hub 126, one or more surfaces forming the actuating morphology 342 can contact one or more surfaces forming the first groove 340 of the first boss 328 or the second groove of the second boss 330.

[0114] In one embodiment, the face ring 302 may include more and / or different retaining features (e.g., at one or more inner surfaces 308 of the face ring 302). For example, the actuating feature 342 may be a groove corresponding to a protrusion on the first boss 328 of the center hub 126 and / or a protrusion on the second boss 330 of the center hub 126. In one embodiment, the face ring 302 includes two or more actuating features 342 at one or more inner surfaces 308 of the face ring 302. For example, the face ring 302 includes two circumferential ribs 342 spaced apart from each other and extending away from one or more inner surfaces 308 of the face ring 302.

[0115] In order to attach the spoke array 300 to the center hub 126 (e.g., at the first end 320 or the second end 322 of the center hub 126), a small face ring 302 is arranged around the first boss 328 or the second boss 330, and the small face ring 302 is pushed downward in the direction D (see FIG11) until the small face ring 302 contacts the first flange 324 or the second flange 326 of the center hub 126, and the actuating morphology 342 (e.g., circumferential rib) engages with the first retaining morphology 340 or the second retaining morphology of the center hub 126. For example, when the small face ring 302 is pushed downward toward the first flange 324 or the second flange 326 of the center hub 126 in direction D, the actuating shape body 342 moves into the first groove 340 or the second groove of the center hub 126, and the small face ring 302 and thus the spoke array 300 are at least translated and locked relative to the center hub 126.

[0116] The attachment procedure described with reference to Figures 10 and 11 can be repeated twice for each wheel (e.g., front wheel 54 and rear wheel 56). For example, the spoke array 300 can be attached to the center hub 126 at either the first side 312 or the second side 314. All four spoke arrays 300 (e.g., for each side 312, 314 of each wheel 54, 56) can be assembled in the same manner. A brake rotor or axle end cap can also be used to mechanically capture the small face ring 302 of the spoke array 300.

[0117] In other embodiments, different subsets of the spoke array 300 may be configured differently. For example, the spoke array 300 may be configured for a specific side of a wheel (e.g., at or adjacent to the first end 320 or the second end 322 of the hub 126; corresponding to the first side 160 or the second side 162 of each wheel 54, 56). For example, different subsets of the spoke array 300 may include different braking features 342, which correspond to the first end 320 and the second end 322 of the central hub 126 and / or different recesses adjacent to the first end and the second end (e.g., the first recess 340 and the second recess of the central hub 126). For example, the position of the first recess 340 relative to the first flange 324 along the first boss 328 may be different from the position of the second recess relative to the second flange 326 along the second boss 330. In other words, the distance between the first flange 324 and the first groove 340 may be different from (e.g., greater than or less than) the distance between the second flange 326 and the second groove. Therefore, different spoke arrays 300 may correspond to different center hubs 126, different sides of the center hubs 126, and / or different wheels (e.g., front wheel 54 or rear wheel 56).

[0118] Other configurations are possible. For example, the spoke arrays for different wheels (e.g., front wheel 54 and rear wheel 56) can be configured differently. For example, the spoke array 300 shown in Figures 5 to 11 may be included in one of the front wheel (e.g., front wheel 54) and the rear wheel (e.g., rear wheel 56), and another spoke array may be included in the other of the front wheel and the rear wheel. For example, another spoke array may include more, fewer, and / or different spokes integrated with the facet ring.

[0119] The spoke array 300 can be removably attached to the center hub 126. For example, the spoke array 300 can be removed from the center hub 126 using a standard tool such as a flathead screwdriver. The user can wedge a screwdriver or another tool with a flat edge (e.g., a tool) between the small face ring 302 of the spoke array 300 and the first flange 324 or the second flange 326 of the center hub 126, and rotate or translate the tool to remove the pawl-shaped body 342 of the spoke array 300 from, for example, the corresponding groove (e.g., the first groove 340) of the center hub 126, thereby allowing the spoke array 300 to translate away from the center hub 126.

[0120] Referring to Figures 10 and 11, a plurality of spokes 304 may be at one or more angles (e.g., angle α) relative to the plane P defined by the small facet ring 302, such that each spoke of the plurality of spokes 304 extends to the central portion (e.g., the innermost portion) of the spoke receiving surface of the spoke engagement portion (e.g., the spoke engagement portion 204 of the rim 200). The plurality of spokes 304 may extend through the spoke receiving surface of the rim and may be connected to the rim within the rim. The plurality of spokes 304 may be connected to the rim in any number of ways. For example, each end of the plurality of spokes 304 may be threaded, and the plurality of spokes 304 may be connected to the rim via the threaded ends of the plurality of spokes 304 and threaded connectors. The plurality of spokes 304 may be connected to the rim in other ways.

[0121] The spoke array 300 can be used (e.g., connected to) any number of different types of wheel rims. For example, the spoke array 300 can be used with wheel rims having protrusions assembled as tire retaining morphology bodies, single-walled wheel rims, double-walled wheel rims, tubular wheel rims and / or other types of wheel rims.

[0122] The facet ring 302 of the spoke array 300 can be formed in any number of different ways. For example, the facet ring 302 of the spoke array 300 (e.g., one or more inner surfaces 308 of the facet ring 302) can be formed into any number of polygons. In one embodiment, one or more inner surfaces 308 of the facet ring 302 are formed into a shape with facets optimized for transmitting torque loads between the central hub 126 and the plurality of spokes 304 of the spoke array 300. In different embodiments, one or more inner surfaces 308 of the facet ring 302 can be formed into a square, pentagon, hexagon, heptagon, octagon, another polygon, a polygon with a leaf-shaped interface, or another shape.

[0123] Figures 13 to 15 illustrate examples of spoke arrays having central flanges of different shapes. Figure 13 shows a spoke array 400, which includes a central flange 402 (e.g., a small facet ring) and a plurality of spokes 404 integral with and extending away from the small facet ring 402. The small facet ring 402 has, for example, six inner surfaces 406 forming hexagons (e.g., and rounded transition portions 408 between adjacent pairs of the six inner surfaces 406). In this embodiment of the central flange 402, the central hub may include a first boss at a first end of the central hub and a second boss at a second end of the central hub, and the outer surfaces of the first boss and the second boss may be formed into hexagons, which are sized to match the hexagons formed by the inner surfaces of the small facet ring 402.

[0124] Figure 14 shows a spoke array 500, which includes a central flange 502 (e.g., a small facet ring) and a plurality of spokes 504 integral with and extending away from the small facet ring 502. The small facet ring 502 has 24 inner surfaces 506 (e.g., and rounded transition portions 508 between adjacent pairs of the 24 inner surfaces 506) forming, for example, star-shaped polygons. In this embodiment of the central flange 502, the central hub may include a first boss at a first end of the central hub and a second boss at a second end of the central hub, and the outer surfaces of the first boss and the second boss may form star-shaped polygons, which are sized to match the star-shaped polygons formed by the inner surfaces of the small facet ring 502.

[0125] Figure 15 illustrates a spoke array 600, which includes a central flange 602 (e.g., a facet ring) and a plurality of spokes 604 integral with and extending away from the facet ring 602. The facet ring 602 has five inner surfaces 606, for example, forming pentagons. In this embodiment of the central flange 602, the central hub may include a first boss at a first end of the central hub and a second boss at a second end of the central hub, and the outer surfaces of the first boss and the second boss may form pentagons, which are sized to match the pentagons formed by the inner surfaces of the facet ring 602. The facet ring 602 may also include convex curved transition portions 608 (e.g., leaf-shaped interfaces) between adjacent pairs of the five inner surfaces 606.

[0126] In one embodiment, a lamination pattern for a composite material layer for a spoke array (e.g., spoke array 300, 400, 500, or 600) is provided prior to the curing process, for example, to form spoke array 300. After the curing process, the composite material layer may be part of an integral spoke array 300. The resulting integral spoke array 300 may be formed from a composite laminate comprising one or more composite materials or multiple compressed layers.

[0127] Figure 16 illustrates one embodiment of a strip 700 of a composite material (e.g., a first composite material). The composite material includes a polymer-based matrix 702 and reinforcing fibers 704. The polymer-based material can be any number of materials, including, for example, plastics, acrylics, resins, epoxy resins, another polymer-based material, or any combination thereof. The reinforcing fibers can be carbon fibers. Other polymer-based materials and / or other reinforcing fibers can be used.

[0128] Fibers 704 extend along a finite length l of strip 700. In one embodiment, fibers 704 extend in the principal strength direction of strip 700 (e.g., along the length l of strip 700). For example, strip 700 has a unidirectional fiber orientation along length l. In another embodiment, some of the fibers 700 do not extend in the principal strength direction (e.g., less than 20% of the fibers, less than 10% of the fibers, or less than 5% of the fibers). Strip 700 can be any number of shapes and / or sizes. For example, strip 700 is rectangular. Other shapes, such as square strips and non-rectangular parallelogram strips, can be provided. Strip 700 also includes a width w perpendicular to length l. Length l can be partially defined by, for example, the length of one of the spokes 304 of a plurality of spokes in a spoke array. In one embodiment, the width w of strip 700 is between 10 mm and 30 mm. For example, the width w of strip 700 is 20 mm. In other embodiments, the strip 700 is wider or narrower. A smaller strip width allows for better optimization of fiber orientation, but at the cost of increased manufacturing complexity.

[0129] For example, the strip 700 provides ultimate strength in the direction of the fiber texture. Therefore, a fiber arrangement can be provided, for example, along the spokes of a plurality of spokes 304. Figures 17A to 17D show examples of continuous fiber paths, for example, within a spoke array 300. In the examples of Figures 17A to 17D, the plurality of spokes 304 includes, for example, ten spokes 304a to 304j. In the first example of Figure 17A, the continuous fiber path 800 forms a first spoke 304a and a sixth spoke 304f among the plurality of spokes 304. The first spoke 304a and the sixth spoke 304f are at an obtuse angle (e.g., 160° or 165°) relative to each other. The continuous fiber path 800 forms a portion of a facet ring 302 (e.g., at least a portion of one side of the facet ring 302). The continuous fiber path 800 is repeated four more times to form the remaining spokes in the plurality of spokes 304 (e.g., second spoke 304b, third spoke 304c, fourth spoke 304d, fifth spoke 304e, seventh spoke 304g, eighth spoke 304h, ninth spoke 304i and tenth spoke 304j) and the remainder of the small facet ring 302.

[0130] In the second example of FIG17B, the continuous fiber path 802 forms a first spoke 304a and an eighth spoke 304h among a plurality of spokes 304. The first spoke 304a and the eighth spoke 304h form an obtuse angle (e.g., 100° or 115°) relative to each other. The obtuse angle shown by the continuous fiber path 802 of FIG17B is smaller than the obtuse angle shown by the continuous fiber path 800 of FIG17A. The continuous fiber path 802 forms a portion of the facet ring 302 (e.g., at least a portion of both sides of the facet ring 302). The continuous fiber path 802 is repeated four more times to form the remaining spokes in the plurality of spokes 304 (e.g., second spoke 304b, third spoke 304c, fourth spoke 304d, fifth spoke 304e, sixth spoke 304f, seventh spoke 304g, ninth spoke 304i and tenth spoke 304j) and the remainder of the facet ring 302.

[0131] In the third example of FIG17C, the continuous fiber path 804 forms the first spoke 304a and the tenth spoke 304j among a plurality of spokes 304. The first spoke 304a and the tenth spoke 304j form an acute angle (e.g., 35° or 40°) relative to each other. The continuous fiber path 804 forms a portion of the facet ring 302 (e.g., at least a portion of three sides of the facet ring 302). The continuous fiber path 804 is repeated four more times to form the remaining spokes among the plurality of spokes 304 (e.g., the second spoke 304b, the third spoke 304c, the fourth spoke 304d, the fifth spoke 304e, the sixth spoke 304f, the seventh spoke 304g, the eighth spoke 304h, and the ninth spoke 304i) and the remaining portion of the facet ring 302.

[0132] In the fourth example of FIG17D, the continuous fiber path 806 forms a first spoke 304a and a second spoke 304b among a plurality of spokes 304. The first spoke 304a and the second spoke 304b form an acute angle (e.g., 40° or 45°) relative to each other. The acute angle shown by the continuous fiber path 806 of FIG17D may be less than, equal to or greater than the acute angle shown by the continuous fiber path 804 of FIG17C. The continuous fiber path 806 forms a portion of the facet ring 302 (e.g., at least a portion of the four sides of the facet ring 302). The continuous fiber path 806 is repeated four more times to form the remaining spokes of the plurality of spokes 304 (e.g., third spoke 304c, fourth spoke 304d, fifth spoke 304e, sixth spoke 304f, seventh spoke 304g, eighth spoke 304h, ninth spoke 304i, and tenth spoke 304j) and the remainder of the facet ring 302. In other embodiments, other continuous fiber paths may be provided.

[0133] Figure 18 illustrates a method 900 for manufacturing a bicycle component (e.g., spoke array 300) for a bicycle (e.g., bicycle 50). The actions of method 900 presented below are intended to be illustrative. In some embodiments, method 900 may be implemented using one or more additional actions not described and / or not using one or more of the described actions. Furthermore, the order of actions of method 900 illustrated in Figure 18 and described below is not intended to be limiting.

[0134] In action 902, at least one layer (e.g., one layer) of the first composite material is positioned within a mold. The first composite material includes a first polymer-based matrix and first reinforcing fiber. In one embodiment, the fiber orientation of the first reinforcing fiber of the first composite material layer is unidirectional along the length of the respective layer.

[0135] The first composite material layer may be any number of shapes and / or sizes. For example, the first composite material layer may be rectangular and may have a length at least twice the length of the spokes of the wheel to be manufactured. Other shapes and / or sizes may be provided.

[0136] The first polymer-based material may be or include any number of polymer-based materials, including, for example, thermoplastic plastics, thermosetting matrices, or combinations thereof. The fibers of the first reinforcing material may be or include any number of different types of fibers, including, for example, carbon fibers, glass fibers, flax fibers, kenaf fibers, hemp fibers, jute fibers, jute fibers, jute fibers, or any combination thereof. Other polymer-based materials and / or other reinforcing materials may be used in the first composite material.

[0137] In one embodiment, the first composite material layer is positioned within a mold such that the first composite material layer forms at least a portion of the spokes and central flange (e.g., small face ring) of the spoke array to be manufactured. In other embodiments, the first composite material layer is positioned within a mold such that the first composite material layer forms at least a portion of another portion of the spoke array to be manufactured (e.g., another spoke of the spoke array).

[0138] In action 904, at least one layer (e.g., one layer) of the second composite material is positioned within a mold such that the layer of the second composite material is adjacent to and / or overlaps with a layer of the first composite material (e.g., within a small facet ring). The second composite material includes a matrix of a second polymer-based material and fibers of a second reinforcing material. The second polymer-based material may be the same as or different from the first polymer-based material, and / or the second reinforcing material may be the same as or different from the first reinforcing material.

[0139] The second polymer-based material may be or include any number of polymer-based materials, including, for example, plastics, acrylics, resins, epoxy resins, or any combination thereof. The fibers of the second reinforcing material may be or include any number of different types of fibers, including, for example, carbon fibers, glass fibers, flax fibers, kenaf fibers, hemp fibers, jute fibers, jute fibers, ramie fibers, or any combination thereof. Other polymer-based materials and / or other reinforcing materials may be used in the second composite material.

[0140] The second composite material layer can be any number of shapes and / or sizes. For example, the second composite material layer can be rectangular and can have a length at least twice the length of the spokes of the spoke array to be manufactured. Other shapes and / or sizes can be provided. In one embodiment, the second composite material layer is longer than the first composite material layer. In another embodiment, the second composite material layer has the same size (e.g., length) as the first composite material layer.

[0141] In one embodiment, the second composite material layer is positioned within a mold such that the second composite material layer forms at least a portion of the spokes and small facets of the spoke array to be manufactured. In other embodiments, the second composite material layer is positioned within a mold such that the second composite material layer forms at least a portion of another portion of the spoke array to be manufactured (e.g., another spoke of the spoke array).

[0142] Actions 902 and / or 904 may be repeated any number of times to form a laminated pattern of the bicycle assembly. In one embodiment, actions 902 and / or 904 may be repeated with one or more additional actions, wherein one or more layers of other composite materials are positioned any number of times to, for example, form a laminated pattern. For example, the second composite material may be the same as the first composite material, and action 904 may be repeated three additional times, such that the laminated pattern is used for ten spokes.

[0143] In action 906, a bicycle assembly is formed. Forming the bicycle assembly includes forming a composite laminate (e.g., a stack) within a mold, comprising at least a layer of a first composite material and a layer of a second composite material. In one embodiment, forming the bicycle assembly includes forming a composite laminate within a mold, comprising at least a layer of a first composite material, a layer of a second composite material, and a layer of a third composite material (e.g., the same as or different from the first composite material and / or the second composite material).

[0144] The mold can be used to form all or part of a bicycle component. For example, for a spoke array, the mold can be divided into multiple sections to allow entry into the mold when at least a first layer of material is positioned in action 902 and a second layer of material is positioned in action 904. For example, the mold can be divided into multiple radial sections (e.g., two radial sections) and / or multiple parts (e.g., a top part and a bottom part).

[0145] Forming a composite laminate may include shaping and curing the composite laminate, for example, within a mold. For instance, at least a first composite layer and a second composite layer may be positioned within the mold and shaped using an inflatable bladder within the mold. The composite laminate may be shaped in other ways.

[0146] Once formed, the composite laminate can be cured in any number of ways, including, for example, by pressure curing, autoclave curing, or oven curing of the composite laminate comprising at least a layer of the first composite material and a layer of the second composite material. Other types of curing may be used.

[0147] The illustrations of the embodiments described herein are intended to provide a general understanding of the structure of various embodiments. These illustrations are not intended to constitute a complete description of all elements and features of devices and systems utilizing the structures or methods described herein. Many other embodiments will become apparent to those skilled in the art upon review of this disclosure. Other embodiments may be utilized and derived from this disclosure, allowing for structural and logical substitutions and changes without departing from the scope of this disclosure. Furthermore, the illustrations are representative only and may not be drawn to scale. Some scales in the illustrations may be enlarged, while others may be minimized. Therefore, this disclosure and the illustrations should be considered illustrative rather than restrictive.

[0148] Although this specification contains numerous details, such details should not be considered as limiting the scope of the invention or any claims that may be made, but rather as descriptions of features specific to particular embodiments of the invention. Certain features described in this specification in the context of individual embodiments may also be implemented in combination in a single embodiment. Conversely, various features described in the context of a single embodiment may also be implemented separately in multiple embodiments or in any suitable sub-combination. Furthermore, although features may be described above as functioning in certain combinations and even initially claimed in this manner, one or more features from the claimed combination may be removed from that combination in some cases, and the claimed combination may be for sub-combinations or variations thereof.

[0149] Similarly, although operations and / or actions are depicted in the diagrams and described in a particular order herein, this should not be construed as requiring such operations to be performed in the particular order shown or in sequential order, or to perform all the illustrated operations in order to achieve the desired result.

[0150] For convenience only and without intending to voluntarily limit the scope of this application to any particular invention or inventive concept, one or more embodiments of this disclosure may be referred to herein individually and / or collectively by the term "invention". Furthermore, although specific embodiments have been illustrated and described herein, it should be understood that any subsequent configurations designed to achieve the same or similar purpose may replace the specific embodiments shown. This disclosure is intended to cover any and all subsequent adaptations or variations of the various embodiments. For those skilled in the art, combinations of the above embodiments with other embodiments not specifically described herein will be apparent upon review of this specification.

[0151] This summary of disclosure is provided to comply with 37 CFR §1.72(b), and it should be understood at the time of filing that it is not intended to interpret or limit the scope or meaning of the claims. Furthermore, in the foregoing embodiments, various features may be grouped together or described in a single embodiment for the purpose of simplifying this disclosure. This disclosure should not be construed as reflecting an intention that the claimed embodiments require more features than explicitly described in the various technical solutions. In fact, as reflected in the following claims, the subject matter of the invention may address fewer than all features of any of the disclosed embodiments. Therefore, the following claims are incorporated into the embodiments, wherein each technical solution, in itself, is as if it were a separate definition of the claimed subject matter.

[0152] The foregoing embodiments are intended to be illustrative rather than restrictive, and it should be understood that the following claims, including all equivalents, are intended to define the scope of the invention. The claims should not be construed as limited to the order or elements described unless stated otherwise. Therefore, all embodiments appearing within the scope and spirit of the following claims and their equivalents are claimed as the invention. [Simplified Explanation of the Diagram]

[0028] The objectives, features, and advantages of the present invention will become apparent after reading the following description in conjunction with the accompanying drawings, in which:

[0029] Figure 1 is a side view of a bicycle that can be constructed to utilize wheels including a spoke array;

[0030] Figure 2 is a perspective view of one embodiment of a wheel for a bicycle, such as the bicycle in Figure 1;

[0031] Figure 3 is a perspective view of one embodiment of a wheel rim, such as the wheel in Figure 2;

[0032] Figure 4 is a cross-section of the wheel rim in Figure 3;

[0033] Figure 5 is a close-up perspective view of one part of the wheel in Figure 2;

[0034] Figure 6 is a top view of a first example of a spoke array for a bicycle wheel, such as the wheel in Figure 2;

[0035] Figure 7 is a first close-up perspective view of the spoke array in Figure 6;

[0036] Figure 8 is a second close-up perspective view of the spoke array in Figure 6;

[0037] Figure 9 is a close-up perspective view of the center hub of a bicycle wheel, such as the wheel in Figure 2;

[0038] Figure 10 is a cross-sectional view of the first side of the spoke assembly before the spoke array is attached to the central hub;

[0039] Figure 11 is a cross-sectional view of the spoke assembly of Figure 10 after the spoke array has been attached to the center hub;

[0040] Figure 12 is a perspective view of the second side of the spoke assembly of Figure 10 after the spoke array has been attached to the center hub;

[0041] Figure 13 is a top view of the second example of the spoke array;

[0042] Figure 14 is a top view of the third example of the spoke array;

[0043] Figure 15 is a top view of the fourth example of the spoke array;

[0044] Figure 16 is a top view of the composite material strip;

[0045] Figures 17A to 17D show different examples of continuous fiber paths;

[0046] Figure 18 is a flowchart of one embodiment of a method for manufacturing wheel rims;

[0047] Figure 19 is a cross-sectional view of a wheel rim for a bicycle, such as the bicycle in Figure 1;

[0048] Figure 20 is a close-up view of the interface between the spokes and the rim, such as the rim in Figure 19;

[0049] Figure 21 shows a first embodiment of the interface structure, which is such as the interface structure seen in Figure 19;

[0050] Figure 22 shows a second embodiment of the interface structure;

[0051] Figure 23 shows a third embodiment of the interface structure; and

[0052] Figure 24 shows the fourth embodiment of the interface structure.

Claims

1. A wheel for a bicycle, the wheel comprising: a central hub having a first end and a second end opposite to the first end, wherein the central hub is configured for rotatable attachment to the bicycle; a rim including a radially inner portion disposed along an inner circumference of the rim; a first spoke array removably attached to the central hub and the radially inner portion of the rim, the first spoke array being located on a first side of the wheel and including: a first central flange; and a plurality of first spokes integral with and extending away from the first central flange to form a first single component; and a second spoke array removably attached to the central hub and the radially inner portion of the rim, the second spoke array being located on a second side of the wheel opposite to the first side of the wheel, the second spoke array including: A second central flange; and a plurality of second spokes integral with and extending away from the second central flange, thereby forming a second single component.

2. The wheel of claim 1, wherein the central hub includes a first flange and a second flange, the first flange being closer to a first end of the central hub than to a second end of the central hub, and the second flange being closer to a second end of the central hub than to a first end of the central hub, wherein the first spoke array is removably attached to the first flange of the central hub, and the second spoke array is removably attached to the second flange of the central hub.

3. The wheel of claim 1, wherein the first central flange of the first spoke array and the plurality of first spokes are made of a first material, and the second central flange of the second spoke array and the plurality of second spokes are made of a second material.

4. The wheel of claim 3, wherein the first material and the second material are the same carbon fiber composite material.

5. The wheel of claim 3, wherein the rim further comprises: a first sidewall; a second sidewall spaced apart from the first sidewall, wherein the first sidewall and the second sidewall extend radially outward from the radially inner portion; and a radially outer tire engagement portion disposed along one outer circumference of the rim, the radially outer tire engagement portion extending from the first sidewall and the second sidewall respectively, and wherein the first sidewall, the second sidewall, the radially outer tire engagement portion and the radially inner portion of the rim are made of a third material, the third material being a carbon fiber composite material.

6. The wheel of claim 2, wherein the first central flange is a first small ring and the second central flange is a second small ring.

7. The wheel of claim 6, wherein each of the first and second small face rings has an inner surface shaped as a square, a pentagon, a hexagon, a heptagon, or an octagon.

8. The wheel of claim 7, wherein the central hub further includes a first boss extending between the first flange and the first end, and a second boss extending between the second flange and the second end, wherein one outer surface of the first boss has the same shape as the inner surface of the first facet ring, and one outer surface of the second boss has the same shape as the inner surface of the second facet ring.

9. The wheel of claim 8, wherein the first boss includes a first retaining shape at the outer surface of the first boss, and the first facet ring includes a second retaining shape at the inner surface of the first facet ring, the second retaining shape being configured to interact with the first retaining shape such that the first spoke array is attached to the center hub, and wherein the second boss includes a third retaining shape at the outer surface of the second boss, and the second facet ring includes a fourth retaining shape at the inner surface of the second facet ring, the fourth retaining shape being configured to interact with the third retaining shape such that the second spoke array is attached to the center hub.

10. The wheel of claim 9, wherein the first retaining shape is a first braking shape extending into the first boss, and the second retaining shape is a second braking shape extending away from the inner surface of the first small facet ring, and wherein the third retaining shape is a third braking shape extending into the second boss, and the fourth retaining shape is a fourth braking shape extending away from the inner surface of the second small facet ring.

11. The wheel of claim 1 further includes a spoke interface structure comprising a spoke joint, a spoke engagement structure and a tension adjustment element, wherein the tension adjustment element is located within the rim and above the spoke joint.

12. A spoke array removably attachable to a central hub and a rim of a wheel for a bicycle, such that the spoke array forms all the spokes on one side of the wheel, the spoke array comprising: a central flange; and a plurality of spokes integral with and extending away from the central flange, such that they form a single component.

13. The spoke array of claim 12, wherein the central flange and the plurality of spokes integral with the central flange are made of a carbon fiber composite material, and wherein the carbon fiber composite material comprises a polymer-based matrix and reinforcing fibers, the reinforcing fibers being carbon fibers.

14. The spoke array of claim 13, wherein one continuous fiber of the carbon fibers extends via the central flange from one of the first spokes to one of the second spokes of the plurality of spokes.

15. The spoke array of claim 14, wherein the first spoke is at an angle relative to the second spoke.

16. The spoke array as requested in item 15, wherein the angle is an acute angle.

17. The spoke array of claim 12, wherein the central flange is a small annular face with an inner surface shaped as a square, a pentagon, a hexagon, a heptagon, or an octagon.

18. The spoke array of claim 17, wherein the facet ring includes a shape-retaining body at one of the inner surfaces of the facet ring.

19. The spoke array of claim 18, wherein the retaining shape body is a protrusion extending radially inward from the inner surface of the small facet ring.

20. The spoke array of claim 19, wherein the protrusion is a circumferential rib extending around one of the inner surfaces of the small facet ring.

Images