Composite Bicycle Rim Perforation via Mould Displacement
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Solution Overview
Problem
The existing manufacturing processes for bicycle wheel rims made of composite materials are inefficient, requiring separate perforation steps that increase manufacturing time and cost, and can result in burrs and sheared fibers, posing safety hazards and reducing the strength of the rim.
Innovation Solution
A process where perforated spoke attachment seats are formed before moulding the composite material, using a pointed tool to displace fibers within the mould, eliminating the need for subsequent perforation and allowing for stronger, burr-free rims with improved safety and reduced manufacturing time and cost.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If separate perforation steps are performed after moulding, then spoke attachment seats can be made in the rim, but manufacturing time increases and production cost increases
Solution Approach 1:
The patent merges the perforation operation with the moulding operation by integrating the perforation tool into the mould itself. The perforation tool is positioned in the mould to define the position and direction of spoke attachment seats, allowing both moulding and perforation to occur simultaneously in a single operational step, thereby eliminating separate post-moulding perforation steps and reducing manufacturing time.
2Ease of manufacture
If separate perforation steps are performed after moulding, then spoke attachment seats can be made in the rim, but production cost increases
Solution Approach 1:
The patent combines the perforation function with the moulding process by incorporating a perforation tool directly into the mould structure. This integration eliminates the need for separate perforation equipment, programming, and operational steps, thereby reducing production costs while maintaining the ability to create precisely positioned spoke attachment seats.
3Ease of manufacture
If material removal machining is used for perforation, then holes can be made in the rim, but burrs and sheared fibers are created posing safety hazards
Solution Approach 1:
The patent performs the perforation action during the moulding process itself, before the composite material fully cures and hardens. The perforation tool, integrated into the mould, creates holes by displacing and redistributing the pliable composite material rather than removing it through cutting. This preliminary action during the pliable state avoids the creation of burrs and sheared fibers that would occur with post-curing removal machining.
4Ease of manufacture
If material removal machining is used for perforation, then holes can be made in the rim, but fiber damage reduces the strength of the rim
Solution Approach 1:
The patent performs perforation during the moulding process while the composite material is still pliable and未固化. The integrated perforation tool creates holes by displacing and redistributing the material rather than removing it through cutting. This preserves the continuity and integrity of the fiber reinforcement, maintaining rim strength while still achieving the necessary spoke attachment seat geometry.
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
This process saves time and cost by integrating perforation into the moulding step, producing stronger rims with reduced fiber damage and safety risks, while enabling diversification of rims according to different spoke patterns during moulding.
Implementation Method 1
forming at least one perforated spoke attachment seat in said at least one part of bicycle rim with displacement of structural fibre before said moulding step
Data Source
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AI summary
A bicycle rim (39) comprising a wall, a plurality of perforated spoke attachment seats (4), and an insert (15) at least one of said perforated seats (4), wherein said insert (15) comprises a first surface configured for shape-coupling with the rim (39) in the proximity of said at least one spoke attachment seat (4) of the rim (39), and has a through hole (16), said insert (15) being constrained to said rim (39).