Composite Bicycle Rim Surface Using a Non-Woven Outer Layer
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Solution Overview
Problem
The manufacturing of bicycle rims from fibrous composite materials is complex, costly, and prone to errors, with high-quality surfaces being difficult to achieve directly from the mold due to optical defects like air pockets, which necessitates extensive refinishing and increases production costs.
Innovation Solution
A bicycle rim with a visible surface formed by a thin non-woven layer over a supporting structure of prepreg layers, which simplifies manufacturing, reduces errors, and enhances surface quality without the need for extensive refinishing, using a composite layer comprising prepreg and non-woven layers to improve homogeneity and stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If bicycle rims are manufactured from fibrous composite materials using traditional methods, then weight reduction and stability are achieved, but manufacturing complexity increases and surface quality deteriorates due to optical defects
Solution Approach 1:
The patent employs a composite layer combining a non-woven layer and a woven layer, where the non-woven layer provides a smooth visible surface while the woven layer provides structural strength. This composite structure allows direct molding without extensive refinishing, reducing manufacturing complexity while maintaining weight reduction benefits.
Solution Approach 2:
The patent applies different material properties to different regions of the rim structure. The non-woven layer is positioned specifically at the visible outer surface where optical quality is critical, while the woven layer provides structural support in load-bearing regions. This localized material differentiation resolves the contradiction between surface quality and manufacturing complexity.
2Stability of the object's composition
If traditional fibrous composite manufacturing methods are used, then structural stability is maintained, but surface quality deteriorates requiring extensive refinishing
Solution Approach 1:
The composite layer combines a non-woven layer with a woven layer, where each layer contributes different properties. The non-woven layer provides a smooth, defect-free visible surface, while the woven layer ensures structural stability. This resolves the contradiction by integrating both surface quality and structural stability requirements into a single composite structure.
Solution Approach 2:
The patent positions the non-woven layer specifically at the visible outer surface where optical quality is critical, while the woven layer provides structural support in load-bearing regions. This localized material differentiation ensures high surface quality without compromising structural stability.
3Manufacturing precision
If varnish coating is applied to mask optical defects, then surface quality improves, but manufacturing complexity and cost increase
Solution Approach 1:
The patent incorporates the non-woven layer into the composite structure before molding, so that the smooth visible surface is formed during the primary manufacturing process itself. This preliminary action eliminates the need for subsequent varnishing or refinishing operations, reducing manufacturing complexity while maintaining high surface quality.
4Adaptability or versatility
If manual manufacturing steps are used, then flexibility is maintained, but productivity decreases and error susceptibility increases
Solution Approach 1:
The pre-fabricated composite layer with integrated non-woven and woven layers can be handled as a single unit during molding, enabling easier automation compared to traditional multi-step manual processes. This maintains design flexibility while improving productivity and reducing error susceptibility.
Data Source
AI summary
A bicycle rim for bicycles with a rim body with a visible surface perceptible in proper operation, wherein a supporting structure of the rim body is made from fibrous composite materials of prepreg layers is disclosed. The rim body includes rim flanks disposed opposite one another, a rim well, and a rim base. The visible surface is formed by a thin non-woven layer on the supporting structure, so as to form directly during manufacturing, an optically appealing, visible surface on the rim body, involving no postprocessing. The non-woven layer forms on the rim body, an outer layer of a composite layer. The composite layer includes a prepreg layer and the non-woven layer.