Composite Bicycle Spoke With Integrated Ends for Low-Maintenance Wheels
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Solution Overview
Problem
Existing bicycle wheel spokes made of metal or fiber composite materials face challenges in manufacturing complexity, weight, and maintenance sustainability, with metal spokes being heavy and fiber composite spokes requiring complex manufacturing and frequent replacement.
Innovation Solution
A spoke made of fiber composite material with integrated end pieces, featuring long reinforcing fibers extending through the center piece and end pieces, manufactured via pultrusion and injection molding, forming a one-piece structure without adhesive layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If metal spokes are used, then reliability and ease of manufacture are improved, but weight increases
Solution Approach 1:
The patent applies composite materials by combining metal end pieces with a fiber-reinforced plastic spoke body. This hybrid construction leverages the high strength and ease of connection of metal at the connection points, while using the low-weight fiber-reinforced plastic for the main spoke body, thus reducing overall weight while maintaining reliability.
2Weight of moving object
If fiber composite material spokes are used, then weight is reduced, but manufacturing complexity increases
Solution Approach 1:
The patent segments the spoke into distinct functional parts: metal end pieces for connection and a fiber-reinforced plastic body for weight reduction. The end pieces are manufactured separately and then attached to the spoke body, allowing each component to be optimized independently through suitable manufacturing processes (metalworking for end pieces, pultrusion or injection molding for the body).
Solution Approach 2:
The patent merges metal end pieces with a fiber-reinforced plastic spoke body into a hybrid construction. This combination allows the benefits of both materials to be realized: the metal provides strong, reliable connections while the composite material provides weight reduction, and the separate manufacturing of components simplifies production.
3Weight of moving object
If fiber composite material spokes are used, then weight is reduced, but ease of repair and sustainability worsen
Solution Approach 1:
By segmenting the spoke into replaceable metal end pieces and a fiber-reinforced plastic body, the patent enables selective replacement of damaged components. If only the end piece is damaged, only that small component needs replacement, not the entire spoke, thereby improving ease of repair and sustainability.
4Adaptability or versatility
If separate end pieces are attached to the spoke body, then adaptability is improved, but manufacturing complexity increases
Solution Approach 1:
The patent merges the metal end pieces with the fiber-reinforced plastic spoke body through robust attachment methods (adhesive bonding, mechanical interlocking, or integration into the molding process). This creates a unified component that maintains the adaptability benefits of separate pieces while simplifying the overall manufacturing process.
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 solution provides a lightweight, easy-to-manufacture spoke with high load capacity and resilience, preventing settling issues and reducing maintenance needs.
Implementation Method 1
The spoke body is manufactured by pultrusion
Implementation Method 2
The end pieces or parts thereof are then injection-molded onto the center piece
Data Source
Figure 1~2
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Figure 7~10
AI summary
A wheel component for bicycles, comprising a straight spoke (10) with a center piece (11) and two end pieces (20, 30) for detachably connecting a hub (108) to a rim (109). At least one of the end pieces (30) comprises a threaded portion (31). The threaded portion (31) is formed integrally with the end piece (20, 30). The spoke is designed without loops and eyelets. The spoke can be supported on a hub (108) and a rim (109) by means of the end pieces (20). The spoke (10) is made of a fiber composite material (2) and comprises a matrix material (3) and reinforcing elements (4) embedded therein. The end pieces (20, 30) are formed integrally with the center piece (11) and each form an end (16, 17) of the spoke (10).At least some of the reinforcing elements (4) are formed as long fibers (5) and extend completely through the central piece (11) and over at least a substantial portion of each of the two end pieces (20, 30). At least one end piece (20, 30) has a cross-sectional area (25, 35) with long fibers (5) embedded therein as reinforcing elements (4) and at least one cross-sectional section (26, 36) without any long fibers (5) embedded therein.