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EP-4037917-B1 - REINFORCED THERMOPLASTIC COMPONENTS AND METHODS OF MANUFACTURE THEREOF

EP4037917B1EP 4037917 B1EP4037917 B1EP 4037917B1EP-4037917-B1

Inventors

  • CHRISTENSEN, JASON
  • STANISH, Joseph
  • CHRISTENSEN, ROLAND

Dates

Publication Date
20260506
Application Date
20200929

Claims (15)

  1. A wheel component, comprising: a rim bed portion (304; 404; 504; 604; 1004, 1084; 1204, 1220; 1504; 1604; 1704; 1804; 1904; 2004; 2156; 2256; 2356; 2456; 2556) at least partially defining a cavity (406; 506; 606; 801; 1001; 1210; 1506; 1606; 1706; 1806; 1906; 2006; 2152; 2252; 2352; 2452; 2552; 2752) and defining an outer annular surface (306; 408; 508; 608; 1008) , the outer annular surface configured to engage a bicycle tire (116); and a main structure portion (310; 410; 510; 610; 1010, 1082; 1224; 1510; 1610; 1712; 1810; 1910; 2010; 2150; 2250; 2350; 2450; 2550) at least partially defining the cavity; wherein: the rim bed portion comprises a reinforced thermoplastic material; the main structure portion comprises a reinforced thermoplastic material (350, 358; 708, 718, 728); and the rim bed portion is bonded to the main structure portion to form an integral structure; the main structure portion comprises a sidewall portion formed from the reinforced thermoplastic material; the reinforced thermoplastic material of the sidewall portion comprises a plurality of overlapping plies defining a radial crossply; the plurality of overlapping plies comprises a first ply (810) having a first edge (812), and a second ply (820) having a second edge (822); the first ply and the second ply overlap one another on the sidewall portion and define an overlapped portion with the first edge oriented substantially transverse to the second edge on the sidewall portion; the overlapped portion extends across at least a majority of a height of the sidewall portion; the main structure portion comprises a first wall portion (412a; 512a; 612a; 1012a, 1082a; 1208a; 1512a; 1612a; 1812a; 1912a; 2012a) defining a first outer side surface and a second wall portion (412b; 512b; 612b; 1012b, 1082b; 1208b; 1512b; 1612b; 1812b; 1912b; 2012b) defining a second outer side surface opposite the first outer side surface; and the first wall portion overlaps the second wall portion in a direction substantially parallel to the outer annular surface.
  2. The wheel component of claim 1, wherein the first edge (812) and the second edge (822) define a bias angle of between 22.5 and 75 degrees relative to a radius extending from the outer annular surface to a center axis of a continuous circle defined by the outer annular surface.
  3. The wheel component of claim 1, wherein: the first ply (810) and the second ply (820) define an arrangement of plies; the wheel component further comprises a plurality of the arrangement of plies disposed in a radial pattern; and the plurality of the arrangement of plies defines the wall portion.
  4. The wheel component of claim 1, wherein the rim bed portion (304; 404; 504; 604; 1004, 1084; 1204, 1220; 1504; 1604; 1704; 1804; 1904; 2004; 2156; 2256; 2356; 2456; 2556) and main structure portion (310; 410; 510; 610; 1010, 1082; 1224; 1510; 1610; 1712; 1810; 1910; 2010; 2150; 2250; 2350; 2450; 2550) are at least one of thermally bonded, chemically bonded, or adhesively bonded.
  5. The wheel component of claim 1, wherein: the main structure portion (310; 410; 510; 610; 1010, 1082; 1224; 1510; 1610; 1712; 1810; 1910; 2010; 2150; 2250; 2350; 2450; 2550) defines an inner annular surface (312; 414; 514; 614; 1014) that is configured to receive a series of spokes (390; 2608); and optionally wherein the main structure portions defines a reinforcing layer along the inner annular surface.
  6. The wheel component of claim 1, wherein: the reinforced thermoplastic material (350, 358; 708, 718, 728) comprises: a thermoplastic material; and fibers (354) disposed within the thermoplastic material; and the fibers include at least one of carbon fibers, glass fibers, Kevlar fibers, or basalt fibers; and optionally wherein the fibers define at least 30% of a volume of the reinforced thermoplastic material.
  7. The wheel component of claim 1, wherein: the rim bed portion (304; 404; 504; 604; 1004, 1084; 1204, 1220; 1504; 1604; 1704; 1804; 1904; 2004; 2156; 2256; 2356; 2456; 2556) and the main structure comprise a continuous reinforced thermoplastic material (350, 358; 708, 718, 728); the rim bed portion has a first external surface; the main structure portion (310; 410; 510; 610; 1010, 1082; 1224; 1510; 1610; 1712; 1810; 1910; 2010; 2150; 2250; 2350; 2450; 2550) has a second external surface that defines the sidewall portion; and the radial crossply defines a continuous, circumferentially uniform distribution of plies on the sidewall portion.
  8. The wheel component of claim 7, wherein: the first external surface and the second external surface are each free of through portions of the wheel component extending between the cavity (406; 506; 606; 801; 1001; 1210; 1506; 1606; 1706; 1806; 1906; 2006; 2152; 2252; 2352; 2452; 2552; 2752) and an external environment that have a cross-dimension of greater than 15 millimeters (mm); and optionally wherein the first external surface cooperates with the second external surface to seal the cavity from an external environment.
  9. The wheel component of claim 7, wherein the cavity (406; 506; 606; 801; 1001; 1210; 1506; 1606; 1706; 1806; 1906; 2006; 2152; 2252; 2352; 2452; 2552; 2752) is formed by maintaining a pressurized region between the rim bed portion (304; 404; 504; 604; 1004, 1084; 1204, 1220; 1504; 1604; 1704; 1804; 1904; 2004; 2156; 2256; 2356; 2456; 2556) and the main structure portion (310; 410; 510; 610; 1010, 1082; 1224; 1510; 1610; 1712; 1810; 1910; 2010; 2150; 2250; 2350; 2450; 2550) during a thermal bonding process.
  10. The wheel component of claim 7, wherein the cavity (406; 506; 606; 801; 1001; 1210; 1506; 1606; 1706; 1806; 1906; 2006; 2152; 2252; 2352; 2452; 2552; 2752) comprises a self-sealing film.
  11. A method of manufacturing a reinforced thermoplastic wheel component, the method comprising: forming a rim bed portion (304; 404; 504; 604; 1004, 1084; 1204, 1220; 1504; 1604; 1704; 1804; 1904; 2004; 2156; 2256; 2356; 2456; 2556) from a reinforced thermoplastic material (350, 358; 708, 718, 728); forming a main structure portion (310; 410; 510; 610; 1010, 1082; 1224; 1510; 1610; 1712; 1810; 1910; 2010; 2150; 2250; 2350; 2450; 2550) from the reinforced thermoplastic material; and thermally bonding the rim bed portion to the main structure portion within a tooling compartment to form a continuous circular component; wherein: the main structure portion comprises a first wall portion and a second wall portion opposite the first wall portion; and the first wall portion overlaps the second wall portion in a direction substantially parallel to a longitudinal axis of the rim bed portion.
  12. The method of claim 11, wherein forming the main structure portion (310; 410; 510; 610; 1010, 1082; 1224; 1510; 1610; 1712; 1810; 1910; 2010; 2150; 2250; 2350; 2450; 2550) comprises arranging a first ply (810) of the reinforced thermoplastic material (350, 358; 708, 718, 728) relative to a second ply (820) of the reinforced thermoplastic material to form a radial crossply.
  13. The method of claim 12, wherein at least one of the first ply (810) or the second ply (820) defines a bias angle relative to a radius extending from an outer annular surface to a center axis of the wheel component of between 22.5 and 75 degrees.
  14. The method of claim 11, wherein the forming of the main structure portion (310; 410; 510; 610; 1010, 1082; 1224; 1510; 1610; 1712; 1810; 1910; 2010; 2150; 2250; 2350; 2450; 2550) comprises stamping the reinforced thermoplastic material (350, 358; 708, 718, 728) to define an inner annular surface (312; 414; 514; 614; 1014) configured for association with a series of spokes (390; 2608).
  15. The method of claim 11, wherein forming the reinforced thermoplastic wheel component comprises heating the reinforced thermoplastic material (350, 358; 708, 718, 728) of the rim bed portion (304; 404; 504; 604; 1004, 1084; 1204, 1220; 1504; 1604; 1704; 1804; 1904; 2004; 2156; 2256; 2356; 2456; 2556) and the reinforced thermoplastic material of the main structure portion (310; 410; 510; 610; 1010, 1082; 1224; 1510; 1610; 1712; 1810; 1910; 2010; 2150; 2250; 2350; 2450; 2550) above a common melting temperature; and optionally wherein forming the reinforced thermoplastic wheel component comprises pressurizing a region of the tooling compartment substantially between the rim bed portion and the main structure portion to define a cavity (406; 506; 606; 801; 1001; 1210; 1506; 1606; 1706; 1806; 1906; 2006; 2152; 2252; 2352; 2452; 2552; 2752).

Description

In this specifications the following non-SI units are used, which may be converted to the respective SI or metric unit according to the following conversion table:| Name of unitSymbolConversion factorSI or metric unitPound / square inchpsi6894.757PaPoundlbs0.454kg FIELD The described embodiments relate generally to high-strength, light-weight structures formed from reinforced thermoplastic materials, and more particularly, to structures formed from reinforced thermoplastic materials that can define a hollow cavity. BACKGROUND Composite materials can include a combination of two or more distinct materials that cooperate in a manner to complement and enhance their respective material properties. For example, composite materials can include a combination of relatively low weight materials and relatively high strength materials in order to produce components having a high strength to weight ratio. Such components can include intricate shapes and designs, including shapes tailored for specialty purposes. Specialty purpose components can, for example, include shapes having contoured surfaces, such as curved exteriors. Components can also have a hollow interior for weight reduction. In many traditional systems, thermoset materials are used to hold reinforcing materials in a matrix. Traditional approaches can produce overly brittle components, and limit component and manufacturing adaptability. Further, traditional manufacturing of components formed from composite materials, and resulting in a shape with a hollow interior, can involve complex, multi-step processes that increase cost and that can result in discontinuities or inconsistencies. As such, the need continues for techniques that can enhance the range of composite material component shapes and structures, without limiting functionality or performance of overall design. US 2007/194619 A1 describes a fiber reinforced plastic bicycle wheel rim, which is formed of six segments per side and formed in a section having precisely formed, machinable brake surfaces and combining inner high modulus fiber reinforced plastic lamination as a main structural body and an outer lamination of improved frictional coefficient materials at the braking surfaces. The main structural body with overlapped individual sheets of unidirectional fiber reinforced plastic, having crossing fibers, in segments, and continuous unidirectional fiber bundles in areas of concentrated load, enables strong, light wheels for sew up or clincher tires to be formed. US 3,369,843 A describes a laminated wheel and method of manufacture. US 2008/265657 A1 describes a method of producing a bicycle rim including, positioning a first quantity of woven fiber strips having a first width and a first length and a second quantity of strips of said woven fibers having a shape different from the first shape to form a first laminated band from the first quantity and the second quantity of strips. A second narrower laminated band is produced. The first band is re-shaped to a V-shaped band before the first band is inserted along the periphery of a mold interior. A core is positioned on the first band and the second band is positioned on the first band. Rim well rings are positioned from outside on the second band, to abut the sides of the second band. A spreader ring is inserted between the rings to join the material near the upper rim flanks and the rim flanges. US 2010/090518 A1 describes a composite rim for use in spoked wheels, such as bicycle wheels, having molded-in spoke holes along with a method of fabricating the composite rim. SUMMARY According to an aspect of the present invention, there is provided a wheel component according to any of claims 1 to 10. According to another aspect of the present invention, there is provided a method of manufacturing a reinforced thermoplastic wheel component according to any of claims 11 to 15. Examples of the present system and method are directed to reinforced thermoplastic components. More specifically, the examples described herein are directed to reinforced thermoplastic components having complex shapes, such as a shape having curved contours, substantially hollow interiors, and/or other properties. The reinforced thermoplastic components described herein can, in certain examples, be used to form a wheel component, such as a wheel used for a bicycle. The reinforced thermoplastic material can be used to form a completely continuous circular component that forms a wheel. The wheel component, or other structure formed by the reinforced thermoplastic material, can be a substantially hollow structure. Disclosed herein are techniques for forming the wheel component using one or more reinforced thermoplastic materials to form the wheel component having the hollow interior and a curved outer surface, including where the wheel component has a substantially circular hollow cavity and a continuous circular outer shape. In one example going beyond the scope of the appended claims,