Composite Bicycle Rim Surface for Post-Processing-Free Manufacture
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Solution Overview
Problem
The production of high-quality bicycle rims made of fiber composite materials is hindered by complex and costly manufacturing processes, high reject rates, and the need for extensive post-processing to achieve desired surface quality, which increases costs and weight.
Innovation Solution
A bicycle rim with a visible surface formed by a thin fleece layer over a supporting structure made of prepreg layers, which simplifies production, reduces defects, and eliminates the need for extensive post-processing, thereby achieving high-quality and cost-effective manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If fiber-reinforced plastics are used to reduce weight and improve stability, then the weight of bicycle rims is reduced and stability is improved, but the production process becomes complex and costly with high reject rates
Solution Approach 1:
The patent uses a composite structure combining a fiber-reinforced plastic supporting structure with a leather or fabric outer layer. The fiber-reinforced plastic provides the necessary strength and weight reduction, while the organic outer layer provides the aesthetic surface quality. This composite approach allows each material to contribute its superior properties without requiring complex post-processing of the fiber-reinforced plastic surface.
2Manufacturing precision
If manual manufacturing steps are used to achieve high surface quality, then surface quality can be improved, but manufacturing costs increase and productivity decreases
Solution Approach 1:
The leather or fabric outer layer is applied to the fiber-reinforced plastic supporting structure before the final curing and demolding process. This preliminary application of the aesthetic layer ensures that the surface quality is established during the molding process itself, eliminating the need for subsequent manual surface treatment, sanding, or painting operations that would reduce productivity.
3Illumination intensity
If lacquer coating is applied to conceal surface defects, then visual appearance is improved, but the weight of the bicycle rim increases and the process becomes more complex
Solution Approach 1:
Instead of applying heavy lacquer coatings to conceal surface defects, the patent uses a thin organic outer layer (leather or fabric) that is applied directly during the molding process. This outer layer serves as the final aesthetic surface without requiring additional coating operations, thereby avoiding the weight penalty and process complexity associated with multiple lacquer coating and curing cycles.
4Manufacturing precision
If extensive post-processing is performed to achieve desired surface quality, then surface quality is improved, but manufacturing costs increase and production time increases
Solution Approach 1:
The patent merges the structural function (fiber-reinforced plastic) and the aesthetic function (leather or fabric outer layer) into a single integrated component produced in one molding operation. This combination eliminates the need for separate post-processing steps to achieve both structural integrity and surface quality, thereby reducing production time and manufacturing costs while maintaining high surface standards.
Data Source
Figure 1~2
Figure 3~4b
Figure 5a~5c
AI summary
A bicycle rim (1) for bicycles (100) with a rim body (2) having a visible surface (8) during intended use, wherein a supporting structure (3) of the rim body (2) is made of a fiber composite material (4) consisting of prepreg layers (5). The rim body (2) comprises opposing rim flanges (21, 22), a rim bed (24), and a rim base (23). The visible surface (8) is formed by a thin nonwoven layer (9) on the supporting structure (3) in order to create an aesthetically pleasing visible surface on the rim body (2) directly during manufacturing without the need for post-processing. The nonwoven layer (9) forms an outer layer (11) of a composite layer (10) on the rim body (2). The composite layer (10) comprises a prepreg layer (5) and the nonwoven layer (9).