Bicycle Rim Fleece Layer Impact Resistance
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Solution Overview
Problem
Existing tubular tire rims face challenges in quality, weight, strength, comfort, and production speed, particularly when made from traditional materials like steel and light metal alloys, and even fiber composite materials.
Innovation Solution
A bicycle rim design featuring a filling layer in the form of a fleece layer or multiple fleece layers, embedded in a braided sleeve and resin, with the fleece layer attached to the outside of the braided sleeve before resin infusion, providing enhanced impact resistance and structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional materials like steel and light metal alloys are used for rim manufacture, then structural strength is achieved, but weight increases and production complexity increases
Solution Approach 1:
The patent employs a composite structure consisting of a braided sleeve made from fiber reinforcement (carbon, aramid, or glass fibers) embedded in resin, combined with a filling layer. This composite material approach achieves high structural strength while reducing weight compared to traditional steel and light metal alloys.
2Weight of moving object
If fiber composite materials are used for rim manufacture, then weight is reduced, but impact resistance and structural integrity deteriorate
Solution Approach 1:
The patent combines fiber reinforcement embedded in resin with an additional filling layer to create a composite structure that maintains high impact resistance while keeping weight low. The combination of materials compensates for the lower impact resistance of individual fiber composite components.
Solution Approach 2:
The filling layer is inserted into the braided sleeve structure, creating a nested configuration where the filling layer is surrounded by the braided reinforcement. This nested structure enhances impact resistance while maintaining the lightweight characteristics of fiber composites.
3Strength
If complex multi-layer structures are implemented to improve strength, then impact resistance increases, but manufacturing complexity and production time increase
Solution Approach 1:
The filling layer is pre-inserted into the braided sleeve before the resin infusion process. This preliminary action simplifies the manufacturing sequence by preparing the composite structure in advance, allowing for more efficient production while maintaining the multi-layer strength-enhancing configuration.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The fleece layer significantly increases impact resistance and rigidity, achieving a balance between weight and reliability, resulting in high-strength and comfortable tubular tire rims with improved braking behavior.
Implementation Method 1
The fleece layer unexpectedly results in a radical increase in impact resistance, i.e. resistance and impact strength
Implementation Method 2
a braided layer with a fleece layer which is embedded in resin
Implementation Method 3
A fleece layer is attached to an outside of the braided sleeve before wetting with resin in a mold using a liquid composite molding process
Data Source
Figure 1
Figure 2~5
AI summary
The invention relates both to a rim (1) for a bicycle, wherein a filling layer (5) is present on the outer surface (4) and the rim (1) is manufactured using liquid composite molding, for example an RTM process or a VARI process, and to a tubular tire rim or clincher rim (1) for a bicycle, with a braided sleeve (2), wherein a nonwoven layer (5) is present on the outer surface (4). The invention also relates to a method for manufacturing a rim (1) according to one of the preceding claims, wherein a nonwoven layer (5) is applied to an outer surface of a braided sleeve (2) in a mold using a liquid composite molding process before being wetted with resin, and to a method for manufacturing a tubular tire rim (1) of the type according to the invention, wherein a nonwoven layer (5) is applied to an outer surface (4) of a braided sleeve (2) before being wetted with resin.