Composite Bicycle Rim Assembly Using Removable Patterns
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Solution Overview
Problem
Existing methods for manufacturing composite bicycle rims result in deficient inter-laminar shear strengths, non-ideal wall thickness, reduced stiffness and strength, and unbalanced rims, while also being time-consuming and largely manual.
Innovation Solution
A method involving the use of removable patterns of material, covered with layers of fiber material, and molded within a pattern of removable material to form a high-performance bicycle rim with enhanced stiffness, strength, and balance, while also reducing manufacturing time through semi-automated processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If composite bicycle rims are manufactured by hand using conventional methods, then the rims can be produced with basic structural integrity, but the inter-laminar shear strength is deficient and the manufacturing time is excessively long (7-8 hours per rim)
Solution Approach 1:
The invention applies preliminary action by pre-forming removable patterns with precise geometries before the composite layup process. These patterns include pre-defined cavities, channels, and surface features that guide the fiber placement and resin infusion, ensuring consistent wall thickness and improved inter-laminar bonding before manufacturing begins
Solution Approach 2:
The removable patterns serve as intermediary objects that mediate between the mold and the composite material. These patterns create the desired internal geometry and control resin flow, acting as a temporary structure that enables automated manufacturing while ensuring high-quality composite consolidation and inter-laminar shear strength
2Manufacturing precision
If conventional hand-laying methods are used to manufacture bicycle rims, then the manufacturing process is flexible, but the wall thickness is non-ideal and the rim stiffness is reduced
Solution Approach 1:
The removable patterns are pre-formed with precise geometries that define the exact wall thickness requirements. The patterns include pre-defined cavities and channels that ensure uniform material distribution and consistent wall thickness throughout the rim structure, eliminating the variability inherent in manual laying methods
Solution Approach 2:
The invention replaces the manual mechanical laying process with an automated resin infusion process guided by removable patterns. This substitution enables precise control over wall thickness and material distribution through the pattern-defined cavities and channels, resulting in uniform thickness and improved rim stiffness
3Productivity
If conventional manufacturing methods are used for bicycle rims, then the production process is simple, but the rims are comparatively unbalanced and the manufacturing time is excessive
Solution Approach 1:
The removable patterns are pre-formed with precise geometries that define the exact wall thickness requirements. The patterns include pre-defined cavities and channels that ensure uniform material distribution and consistent wall thickness throughout the rim structure, eliminating the variability inherent in manual laying methods
Solution Approach 2:
The invention replaces the manual mechanical laying process with an automated resin infusion process guided by removable patterns. This substitution enables precise control over wall thickness and material distribution through the pattern-defined cavities and channels, resulting in uniform thickness and improved rim stiffness
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 method achieves improved durability, stiffness, and balance in bicycle rims, while significantly reducing manufacturing time from several hours to just minutes, resulting in a higher-quality product.
Implementation Method 1
heating said mold to a first temperature in a first temperature range
Implementation Method 2
heating said mold to a first temperature in a first temperature range
Data Source
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Figure 5~6
AI summary
The present invention relates to a method of assembling a rim, in particular a bicycle rim of composite material. The invention further relates to a rim obtainable by such a method.