Composite Bicycle Rim Assembly for Uniform Wall Thickness
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Solution Overview
Problem
Current methods for manufacturing composite bicycle rims result in inadequate inter-laminar shear strengths, non-ideal wall thickness, and unbalanced rims, while being time-consuming and requiring manual labor, which affects their stiffness, strength, and durability.
Innovation Solution
A method involving the use of removable patterns covered with fiber material layers, molded in a controlled temperature environment to achieve uniform thickness and enhanced bonding, reducing manufacturing time from hours to minutes and improving rim quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If composite bicycle rims are manufactured by hand using conventional methods, then lightweight rims can be produced, but the manufacturing time is excessively long (7-8 hours per rim) and the quality is inconsistent
Solution Approach 1:
The patent applies preliminary action by pre-assembling the fiber reinforcement layers on a mandrel before placing them in the mold. This pre-assembly step allows for controlled layering and orientation of fibers, ensuring uniform wall thickness and consistent quality. The mandrel serves as a temporary support structure that maintains the geometric precision of the layered composite structure before final molding, thereby resolving the contradiction between productivity and manufacturing precision.
2Productivity
If conventional manual manufacturing methods are used, then some degree of automation is avoided, but the manufacturing time remains excessive and labor-intensive
Solution Approach 1:
The manufacturing process is segmented into distinct automated stages: (1) automated fiber layer placement on mandrel, (2) automated mold closure, (3) automated resin injection, and (4) automated curing. This segmentation allows each stage to be optimized independently, with automated equipment performing specific tasks efficiently. The mandrel system enables automated handling and positioning, reducing manual labor while maintaining productivity gains.
3Strength
If fiber layers are not properly bonded, then manufacturing complexity is reduced, but inter-laminar shear strength becomes deficient
Solution Approach 1:
The patent utilizes parameter changes by controlling the temperature and pressure conditions during the molding process. The mold is heated to a specific temperature range that activates the resin's bonding properties, while controlled pressure ensures intimate contact between fiber layers. These parameter changes transform the resin from a non-bonding state to a bonding state, achieving high inter-laminar shear strength through controlled physical-chemical transformation rather than complex mechanical bonding mechanisms.
4Strength
If the mold is not heated to controlled temperature, then energy consumption is reduced, but the resin cannot properly cure and bond the fiber layers
Solution Approach 1:
The patent exploits phase transitions by heating the mold to transform the resin from a viscous liquid state to a cured solid state. The controlled heating provides the thermal energy necessary for the resin to undergo polymerization and cross-linking reactions, transitioning from a non-structural to a structural bonding material. This phase transition approach efficiently achieves strong inter-laminar bonding through thermal energy input rather than mechanical or chemical bonding processes.
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 produces bicycle rims with increased stiffness, strength, and reduced unbalance, while significantly reducing manufacturing time, resulting in high-performance composite rims with improved inter-laminar shear strength and surface smoothness.
Implementation Method 1
heating said mold to a first temperature in a first temperature range
Implementation Method 2
heating said mold for curing the material of said rim
Data Source
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.