RIM AND BICYCLE WHEEL WITH WINGS WITH COMPENSATED FLARING

Abstract

A rim has a pair of converging wings connected by at least one bridge.

Description

FIELD OF INVENTION

The present invention refers at least to a rim for a bicycle wheel, to a wheel comprising such a rim and to a process for making such a rim and such a wheel.

BACKGROUND

In common usage, the term rim is often used to refer to a wheel (of a bicycle or other) without a tire. However, in the following description, the term rim means the peripheral part of the wheel of a bicycle to which the tire is fitted. Normally, therefore, a wheel comprises a rim connected to a hub through a plurality of spokes or arms.

Typical configurations of the cross section of a bicycle rim are U-shaped or inverted A-shaped. In U-shaped rims there are two side walls and a radially inner circumferential wall, also known as “lower bridge” or even simply “bridge” (in the absence of other bridges). In inverted A-shaped rims, on the other hand, there is both a “lower bridge” and an “upper bridge”; more specifically, there is a radially inner portion of the cross section of the rim, formed from a chamber defined by the upper bridge (outer in the radial direction), by two side walls and by the lower bridge (inner in the radial direction).

In rims made from composite material, the braking races with parallel braking surfaces are obtained during the molding step of the rim itself. Unlike rims made from metallic material, rims made from composite material have no jointing, since they are already annular from the outset.

At the moment of inflation of the tire the circumferential wings for fitting the tire deform outwards under the pressure of the tire; as a result of this there is a flaring effect of the wings that leads to both an increase in the distance between the wings and therefore between the braking races along the entire circumference, and above all a loss of parallelism of the wings and therefore of the braking races, with a reduction in the braking efficiency of the brake pads when they rest on the braking races and with problems of air seal for wheels with tubeless tires. This flaring effect is shown in FIGS. 1a and 1b and in FIGS. 2a and 2b, for U-shaped 1x and inverted A-shaped rims 1y, respectively. In FIG. 1a, the tire 16 mounted on the rim 1x is deflated and the separation between the rim sides is shown with a distance “A,” whereas in FIG. 1b, the tire is inflated and the distance between the rim sides is shown with a distance “B” where the distance B in each pair of figures is greater than the distance A. In FIG. 2a, the tire 16 mounted on the rim 1y is deflated and the separation between the rim sides is shown with a distance “A,” whereas in FIG. 2b, the tire is inflated and the distance between the rim sides is shown with a distance “B” where the distance B in each pair of figures is greater than the distance A.

It has also been found that in practice known wheels that use the described rims the distance between the wings is not constant along the circumference of the wheel (waving effect), with problems of vibration and noisiness during braking caused by the pads that push upon the wings and with problems of air seal for wheels with tubeless tires.

The waving of the distance between the wings and therefore between the braking races is induced on the rim during the assembly of the wheel. The degree of waving depends upon the type of material used and upon the type of geometry of the section of the rim (shape, length of the side walls, etc.).

A first type of waving, distributed over the entire circumference of the wheel, is caused at the moment when the spokes are tightened, to a particularly marked extent in wheels with the spokes grouped together, since the traction force, oriented towards the centre of the rim in the spoke attachment area due to the spokes being tightened, causes a variation in distance between the wings and therefore between the braking races.

In the case of rims 1x with U-shaped configuration (schematic views of FIGS. 8a-8c in which such views represent a blank of the rim seen from the outside along its extension), the bridge is substantially pulled by the spokes towards the centre of the rim 1x and the wings move towards one another; therefore, the distance between the wings in the spoke attachment area is in the end less than the distance between the wings 7, 8 in the intermediate areas (FIG. 8b). When the tire is mounted on the wheel and inflated, the wings 7, 8 also undergo the flaring effect described above, since they are pushed laterally outwards by the pressure of the tire along the entire circumference of the rim; and therefore the wings move apart (FIG. 8c). The distributed waving effect of the spoke attachment area therefore arises once again on the wheel with the tire inflated, in addition to the flaring effect.

In the case of rims 1y with inverted A-shaped configuration, with spokes attached to the lower bridge (schematic views of FIGS. 9a-9c in which such views represent a blank of the rim 1y seen from the outside along its extension), when the section is pulled by the spokes towards the centre of the rim, due to the presence of the upper bridge, there is a deformation of the wings 7, 8 outwards at the spoke attachment area; therefore, in the end in the spoke attachment areas the distance between the wings is greater than the distance between the wings in the intermediate areas creating the waving effect (FIG. 9b). When the tire 16 is mounted on the wheel and inflated, the wings 7, 8 also undergo the flaring effect described above, being pushed laterally outwards by the pressure of the tire along the entire circumference of the rim; therefore the wings move apart (FIG. 9c). Moreover, because of the different rigidity of the rim in the spoke attachment areas compared to the intermediate areas, due to the traction of the spokes, the waving effect with the tire inflated (FIG. 9c) is increased with respect to the waving effect with the tire deflated (FIG. 9b). In the spoke attachment areas, therefore, the wings subjected to the pressure of the inflated tire undergo a greater deformation than the deformation that they undergo in the intermediate areas. The distributed waving effect of the spoke attachment area arises once again on the wheel with the tire inflated, in addition to the flaring effect.

For both the U-shaped and inverted A-shaped configurations, the variation in distance between the wings in the spoke attachment areas compared to the distance between the wings in the intermediate areas results in a waving effect of the braking races; this waving is distributed, i.e. substantially repeats cyclically along the circumference of the rim according to the distribution of the spokes. This distributed waving occurs both on metallic rims, and on rims made from composite material, since it is not linked to the type of material from which the rim is made nor to the possible presence of a joint.

A second type of waving (FIGS. 10a-10b), not distributed cyclically along the circumference of the rim 1x, 1y but rather localized in a single area, is caused at the moment of inflation of the tire on wheels provided with rims with a joint, both in wheels with single spokes (to which FIGS. 10a and 10b refer) and in wheels with grouped spokes. The inflation of the tire, as stated above, results in an inevitable deformation of the wings 7, 8 that are pushed outwards by the pressure of the tire. However, such a deformation is not homogeneous along the entire circumference of the rim, since at the jointing area 38x the rim 1x, 1y has a greater rigidity than at the other areas of the rim 1x, 1y. In particular, the greater rigidity of the jointing area 38x is due to the welding on the one hand and to the joints inserted on the other (in rims 1x, 1y with welding and joint such an effect is the sum of the two, whereas it is less evident where jointing is carried out with a joint glued to the wall of the chamber of the rim and without welding).

Therefore, the deformation of the wings 7, 8 in the jointing area 38x is less than the deformation of the wings 7, 8 in the rest of the rim 1x, 1y. In the wheel provided with an inflated tire, therefore, the braking surfaces have a narrowing at the jointing area (localized waving), as shown in FIG. 10b. FIG. 10c shows (for a wheel with grouped spokes) both the effect of localized waving in the jointing area 38x, and the distributed waving effect due to the spokes being tightened, as represented in FIGS. 9a-9c. Localized waving is normally of a greater magnitude (about double) compared to distributed waving caused by the spokes being tightened.

SUMMARY

In a first embodiment, a rim, suitable for being coupled with a hub to form a bicycle wheel, comprises a pair of converging wings connected by at least one bridge.

BRIEF DESCRIPTION OF THE DRAWING(S)

FIGS. 1 a and 1b show a wheel with a rim of the prior art with U-shaped configuration, in two configurations with the tire deflated and with the tire inflated, respectively.

FIGS. 2 a and 2b show a wheel with a rim of the prior art with inverted A-shaped configuration, in two configurations with the tire deflated and with the tire inflated, respectively.

FIG. 3 a shows a section of a rim according to the invention, with U-shaped configuration.

FIG. 3 b shows a section of a wheel that uses the rim of FIG. 3a, with the tire mounted and deflated.

FIG. 3 c shows the wheel of FIG. 3b, with the tire inflated.

FIG. 4 a shows a section of a rim according to the invention, with inverted A-shaped configuration.

FIG. 4 b shows a section of a wheel that uses the rim of FIG. 4a, with the tire mounted and deflated.

FIG. 4 c shows the wheel of FIG. 4b, with the tire inflated.

FIGS. 5 a to 5c show the steps of a process for obtaining the rim of FIG. 3a.

FIGS. 6 a to 6c show the steps of a process for obtaining the rim of FIG. 4a.

FIGS. 7 a to 7e show the steps of another process for obtaining the rim of FIG. 4a.

FIGS. 8 a to 8c, 9a to 9c and 10a to 10c show rims of the prior art with the waving effects highlighted; more specifically:

FIG. 8 a shows a rim with U-shaped configuration and with grouped spokes before the spokes are applied and tightened;

FIG. 8 b shows the rim of FIG. 8a after the spokes are tightened; and

FIG. 8 c again shows the rim of FIG. 8a after it has been mounted in a wheel and the tire has been inflated.

FIG. 9 a shows a rim with inverted A-shaped configuration and with grouped spokes before the spokes are applied and tightened.

FIG. 9 b shows the rim of FIG. 9a after the spokes are tightened.

FIG. 9 c again shows the rim of FIG. 9a after it has been mounted in a wheel and the tire has been inflated.

FIG. 10 a shows a rim with single spokes, before it has been mounted in a wheel.

FIG. 10 b shows the rim of FIG. 10a after it has been mounted in a wheel and the tire has been inflated.

FIG. 10 c shows a rim with grouped spokes, after the spokes have been tightened and after it has been mounted in a wheel and the tire has been inflated.

FIG. 11 shows an axonometric view of a rim according to the invention, of the type made from composite material, without a joint, having a section as shown in FIG. 4a.

FIG. 12 shows an axonometric view of a rear wheel with grouped spokes that uses the rim of FIG. 11, without a tire.

FIGS. 13 a and 13b schematically show steps of a process for obtaining the wheel of FIG. 12.

FIG. 14 shows an axonometric view of a rim according to the invention, of the metallic type, with a joint, having a section as shown in FIG. 4a.

FIG. 15 shows an axonometric view of a rear wheel with grouped spokes that uses the rim of FIG. 14, without a tire.

FIGS. 16 a to 16c and 17a to 17c, schematically show process steps for obtaining the wheel of FIG. 15.

FIGS. 18 a to 18c schematically show the steps of a process for obtaining the wheel of FIG. 19b.

FIG. 19 a shows an axonometric view of a rim according to the invention, of the metallic type, with a joint, having a section as shown in FIG. 4a.

FIG. 19 b shows an axonometric view of a front wheel with single spokes that uses the rim of FIG. 19a, without a tire.

FIGS. 20 a to 20d and 21a to 21d, schematically show process steps for obtaining the wheel of FIG. 15.

FIGS. 22 a to 22c schematically show the steps of a process for obtaining the wheel of FIG. 19b.

FIGS. 23 a to 23d, 24a to 24d, 25a to 25e, 26a to 26c schematically show deformation processes of the wings.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Introduction

It is possible to induce an advance deformation in the rim before it is assembled in a wheel in the direction opposite the direction of deformation by flaring that the rim will undergo after inflation of the tire once mounted in a wheel; consequently, the wheel can in the end have a substantially reduced flaring deformation (possibly even zero), with an improvement in the air seal in the case of assembly of a wheel with a tubeless tire.

In the case in which each wing has an outer side on which a braking race is formed, to assist in braking.

The axial distance between the wings should be measured between the outer sides thereof.

In the case in which the rim comprises a plurality of spoke attachment areas, alternating in the circumferential direction with a plurality of intermediate areas in the at least one bridge, the axial distance between the wings at the spoke attachment areas can be different than the axial distance between the wings at the intermediate areas.

In this way, it is possible to induce an advance deformation in the rim before it is assembled in a wheel in the direction opposite the direction of deformation by distributed waving that the rim will undergo afterwards, due to assembly in the wheel; consequently, the wheel can in the end have a substantially reduced distributed waving deformation (possibly even zero), with an improvement in the braking efficiency and improvement of the air seal in the case of assembly of a wheel with a tubeless tire.

In the case in which the rim comprises a single bridge between the pair of wings (U-shaped configuration), the axial distance between the wings at the spoke attachment areas is greater than the axial distance between the wings at the intermediate areas.

In the case in which the rim comprises a lower bridge and at least one upper bridge between the pair of wings (inverted A-shaped configuration or configuration with many chambers), the axial distance between the wings at the spoke attachment areas is less than the axial distance between the wings at the intermediate areas.

The rim can be made from composite material or else metal, from a blank that is extruded, calendared into circular shape and closed upon itself through jointing between the ends of the blank. In this last case, when the rim is mounted in a wheel and the tire is inflated, there is also the drawback of localized waving, and therefore the axial distance between the wings at the jointing area is preferably provided to be greater than the axial distance between the wings at the areas far from the jointing area.

The axial distance between the wings at the jointing area may be greater than the axial distance between the wings at the spoke attachment areas as well as the axial distance between the wings at the intermediate areas.

In a second aspect thereof, the bicycle wheel comprises a hub, a rim, and a plurality of spokes or arms for connecting the rim to the hub, in which the rim comprises a pair of wings for holding a tire connected by at least one bridge, wherein when the tire is dismounted from the wheel or else—if it is mounted—it is flat, the wings converge.

In such a wheel, the advance deformation induced in the rim is in the opposite direction to the direction of deformation by flaring that the rim will undergo after inflation of the tire once mounted in a wheel; consequently, the wheel has a substantially reduced deformation by flaring (possibly even zero), with an improvement in the braking efficiency and improvement of the air seal in the case of assembly of a wheel with a tubeless tire.

When the tire is mounted on the wheel and inflated, the wings converge less or may even be parallel. The deformation by flaring is thus completely compensated.

In the case in which the rim comprises a plurality of spoke attachment areas, alternating in the circumferential direction with a plurality of intermediate areas in the at least one bridge, preferably the wings of the rim deformed by the tension of the spokes are the same distance apart at the spoke attachment areas and at the intermediate areas. The deformation by distributed waving is thus completely compensated.

In the case in which the rim is made from metal from a blank that is extruded, shaped into circular shape and closed upon itself through application of a joint between the ends of the blank, then, when the tire is dismounted from the wheel or else—if it is mounted—it is flat, the axial distance between the wings at the joint is greater than the axial distance between the wings at the areas far from the joint.

When the tire is mounted on the wheel and inflated, the axial distance between the wings at the joint may be equal to the axial distance between the wings at the areas far from the joint. The deformation by localized waving is thus completely compensated.

In a third aspect, a process for making a rim suitable for being mounted in a bicycle wheel, comprises the step of:

a) providing a pair of wings connected by at least one bridge,

wherein in step a) the wings are formed converging.

The process may comprise the step of:

b) providing a plurality of spoke attachment areas and a plurality of intermediate areas, alternating in the circumferential direction, in the at least one bridge;

and in it in step a) it is provided for the wings to be shaped and sized so that the distance between the wings at the spoke attachment areas are different to the distance between the wings at the intermediate areas.

Step a) may provide for forming the blank directly with the wings spaced apart non-uniformly.

Alternatively, according to the method, step a) may comprise the substeps of:

a′) forming the rim with the wings spaced apart between them uniformly along the entire blank;

a″) deforming the wings varying the distance at the spoke attachment areas and/or at the intermediate areas.

Step a″) may comprise bending the wings inwards and/or outwards at the spoke attachment areas and/or at the intermediate areas.

According to an alternative method, step a″) comprises removing material from outer sides of the wings at the spoke attachment areas and/or at the intermediate areas.

The rim is made from metal from a blank that may be extruded, shaped into circular shape and closed upon itself through jointing between the ends of the blank, and the process also comprises the steps of:

c) deforming the wings so that the axial distance between the wings at the jointing area is greater than the axial distance between the wings at the areas far from the jointing area.

In a fourth aspect, a process for making a bicycle wheel comprises the steps of:

a) making a rim comprising a pair of wings connected by at least one bridge;

b) connecting the rim with a hub through spokes or arms;

wherein in step a) the wings are formed converging.

DETAILED DESCRIPTION

Flaring Effect Compensation

FIG. 3 a shows the section of a rim 1 that has a section with U-shaped configuration comprising two side walls 4, 5 and a radially inner circumferential wall 6 (lower bridge). The side walls 4, 5 extend radially outwards to define two circumferential wings 7, 8 for fitting a tire 16. The circumferential wings 7, 8 have outer sides 9, 10 on which braking races 11, 12 are formed that provide braking surfaces on which the two brake pads (not shown) close during braking.

As shown in FIG. 3a, the braking races 11, 12 are not parallel to one another, but rather converge towards each other: their distance apart (and the distance from the middle plane M of the rim 1) decreases as the distance from the centre of the rim 1 increases. The progression shown in the figures is intentionally exaggerated in order to show this clearly; real values for such a narrowing may be of the order of tenths of a mm.

The rim 1 is used to make a wheel 3, together with a hub connected to the rim 1 by spokes (neither the hub nor the spokes are shown in FIGS. 3a to 3c) and to the tire 16, mounted on the rim 1 between the wings 7, 8. When the tire 16 is mounted on the rim 1 (FIG. 3b) and then inflated (FIG. 3c), the wings 7, 8 deform outwards, with a flaring effect. Such flaring is compensated by the original convergence of the wings 7, 8 and therefore in the wheel 3 with the tire 16 inflated the braking races 11, 12 converge less and, at best, are parallel (as shown in FIG. 3c).

FIG. 4 a shows the section of a rim 21 that has an inverted A-shaped section. The radially inner body region is formed from a chamber 22, defined by a radially outer circumferential wall or upper bridge 23, by two side walls 24, 25 and by a radially inner circumferential wall or lower bridge 26. The side walls 24, 25 extend radially outwards to define circumferential wings 27, 28 for fitting a tire 36. The circumferential wings 27, 28 have outer sides 29, 30 on which braking races 31, 32 are formed that provide braking surfaces on which the two brake pads (not shown) close during braking.

As shown in FIG. 4a, the braking races 31, 32 are not parallel to one another, but rather converge: their distance apart (and the distance from the middle plane M of the rim 21) decreases as the distance from the centre of the rim 21 increases, starting substantially from the height of intersection with the upper bridge 23. A typical value of this narrowing may be 0.15 mm for each wing 27, 28, for a total of 0.3 mm.

The rim 21 is used to make a wheel 33, together with a hub connected to the rim 21 by spokes (the hub and the spokes are not shown in FIGS. 4a to 4c, but are shown in FIG. 12) and to a tire 36, mounted on the rim 21 between the wings 27, 28. When the tire 36 is mounted on the rim 21 (FIG. 4b) and then inflated (FIG. 4c), the wings 27, 28 deform outwards, starting substantially from the intersection with the upper bridge 23, with a flaring effect. Such flaring is compensated in the wheel 33 with the tire 36 inflated by the original convergence of the wings 27, 28 and therefore in the wheel 33 with the tire 36 inflated the braking races 31, 32 converge less and, at best, are parallel (as shown in FIG. 4c).

Distributed Waving Effect Compensation

Distributed Waving Effect Compensation on a Rim Made from Composite Material

FIGS. 11 and 12 show perspective views of the rim 21 and the wheel 33.

The wheel 33 represented is a rear wheel, of the type with grouped spokes 35, and comprises the rim 21, a hub 34 and a set of spoke connections 35 between the hub 34 and the rim 21.

The set of spoke connections 35 (also known as spoking) of the wheel 33 comprises twenty-four spokes 35 grouped in eight sets of three. There are therefore eight spoke attachment areas 41-48, each comprising three individual spoke attachment seats, alternating with eight intermediate areas 51-58.

The rim 21 may be made from composite material, for example made by molding and cross linking or setting of a fibrous material, such a carbon fiber, in a matrix of polymeric material. The details on the construction of the rim 21 in general can be found, for example, in EP 1 231 077, incorporated herein by reference as if fully set forth. This type of composite material rim 21 is in one piece, and therefore there is no jointing.

In the rim 21 a hole 37 is formed for housing a valve for retaining air inside the tire 36 (not shown in FIGS. 11 and 12) that can be associated with the outside of the rim 21.

As schematically shown in FIG. 13a, the outer sides 29, 30 of the wings 27, 28 with the braking races 31, 32 are waved: indeed, at each spoke attachment area 41-48, the outer sides 29, 30 of the rim 21 are a shorter distance Da apart in the axial direction (with reference to the axis of the wheel 33) than their distance Di at the intermediate areas 51-58. The progression shown in FIGS. 13a-13c shows the rim's progression caused by inflation, and is intentionally exaggerated for the sake of clarity; real values for Da and Di can, indeed, be Da=20.70 mm and Di=20.80 mm.

The distance in the axial direction between the outer sides 29, 30 varies progressively between the spoke attachment areas 41-48 and the intermediate areas 51-58, as shown by FIG. 13a.

When the wheel 33 is assembled using the rim 21 and the spokes 35 are tightened between the rim 21 and the hub 34, the rim 21, and in particular the wings 27, 28 on whose outer sides 29, 30 the braking races 31, 32 are formed, undergo a deformation (as already explained with reference to the prior art) such that the distance between the wings 27, 28 and more specifically between the outer sides 29, 30 at the spoke attachment areas 41-48 increases. The result is that the distance between the outer sides 29, 30 with the braking races 31, 32 of the rim 21 has lower variations with respect to the rim 21 without spokes (as shown in FIG. 13b). The subsequent assembly of the tire and its inflation determine a further outward deformation of the wings 27, 28 on the rim 21 (as already explained with reference to the prior art) in which in the spoke attachment areas the wings subjected to the pressure of the inflated tire undergo a greater deformation than the deformation that they undergo in the intermediate areas. At best, as shown in FIG. 13c, such a deformation is such that the distance between the outer sides 29, 30 with the braking races 31, 32 of the rim 21 does not vary and remains constant along the entire circumference of the rim 21.

The rim 21 of FIG. 13a can be obtained, in general, according to what is described in the cited document EP 1 231 077, by providing that the shape of the mold in the area for forming the wings has the desired waved shape.

Distributed Waving Effect Compensation on a Rim Made from Metallic Material

FIGS. 14 and 15 show perspective view of a rim 121 and a wheel 133 according to a different embodiment.

The wheel 133 represented is again a rear wheel, of the type with grouped spokes, and comprises the rim 121, a hub 134 and a set of spoke connections 135 between the hub 134 and the rim 121. Unlike the embodiment of FIGS. 11 and 12, the rim 121 is of the metallic type, made through extrusion of a rod of suitable cross section, calendering it and jointing the ends at a jointing area 138. Therefore, FIGS. 4a to 4c are also representative of the section of the rim 121 and of the wheel 133, in circumferential areas different to the jointing area 138. Such FIGS. 4a to 4c therefore also display the reference numerals of the wheel 133 in brackets.

In a position diametrically opposite the jointing area 138, in the rim 121 a hole 137 is made to house a valve for retaining air inside the tire 136 that can be associated with the outside of the rim 121.

The jointing in the area 138 is carried out by butt welding of the ends of the extruded and calendered rod. A pair of full metallic inserts 139, 140 (summarily shown in FIG. 14) are inserted into the chamber 122 of the rim 121, used to allow the ends to be gripped with suitable pincers during welding without the risk of deforming the rim 121.

As an alternative to the welding and to the insertion of the inserts 139, 140, the jointing in the area 138 can take place through a sleeve, inserted with interference and with a possible gluing substance in the inner chamber 122 of the rim 121. Again alternatively, the joining in the area 138 can take place through pins inserted in the wall of the ends of the rim 121.

FIG. 16 a schematically shows a blank of the rim 121 after extrusion, calendering, joining in the jointing area 138 and after the braking races 131, 132 have been formed (for example by turning) on the outer sides 129, 130 of the wings 127, 128.

A deformation is carried out on such a preform of FIG. 16a (for example with one of the processes described hereafter) so that the outer sides 129, 130 of the wings 127, 128 of the rim 121 at the spoke attachment areas 141-148 are a shorter distance Da apart than the distance Di apart of the outer sides 129, 130 of the wings 127, 128 of the rim 121 at the intermediate areas 151-158 (FIG. 16b).

The distance in the axial direction between the outer sides 129, 130 varies progressively between the spoke attachment areas 141-148 and the intermediate areas 151-158, as shown by FIG. 16b.

When the wheel 133 is assembled using the rim 121 and the spokes 135 are tightened between the rim 121 and the hub 134, the rim 121, and in particular the outer sides 129, 130 of the wings 127, 128 on which the braking races 131, 132 are formed, undergo a deformation (as already explained with reference to the prior art) such that the distance between the outer sides 129, 130 at the spoke attachment areas 141-148 increases, without however reaching the distance at the intermediate areas 151-158. The result is that the distance between the outer sides 129, 130 with the braking races 131, 132 of the rim 121 has smaller variations than the rim 121 without spokes, as shown in FIG. 16c. When, finally, the tire 136 is mounted on the wheel 133 and inflated, there is a deformation of the wings 127, 128 outwards with a non-uniform increase in the distance between the outer sides 129, 130 with the braking races 131, 132 along the circumference: in the jointing area 138 the rigidity of the rim 121 is greater and the deformation occurs to a lower extent, whereas in the spoke attachment areas 141-148 the rigidity of the rim 121 is less and the deformation occurs to a greater extent. However, the greater deformation in the spoke attachment areas 141-142 is compensated by the residual inward deformation. In the wheel 133 with the tire 136 inflated, therefore, the distributed waving effect is reduced and, at best, is nonexistent (as shown in FIG. 16d), whereas the localized waving effect in the jointing area 138 due to the joint is not compensated.

FIGS. 17 a-17c show a variant of the steps described in FIGS. 16a-16c for making the same wheel 133, in which first the spokes 135 are tightened and then the deformation of the rim 121 is carried out. The spokes 135 are mounted and tightened on the preform (FIG. 17a). The tightening, as stated, involves an outward deformation of the wings 127, 128 at the spoke attachment areas 141-148 (FIG. 17b). At this point the inward deformation of the wings 127, 128 is carried out (FIG. 17c) at the spoke attachment areas 141-148 to obtain a shorter distance Da compared to the distance Di existing between the wings 127, 128 in the intermediate areas 151-158.

When, finally, the tire 136 is mounted on the wheel 133 and inflated, there is an outward deformation of the wings 127, 128 with a non-uniform increase in the distance between the outer sides 129, 130 with the braking races 131, 132 along the circumference: in the jointing area 138 the rigidity of the rim 121 is greater and the deformation occurs to a lower extent, whereas in the spoke attachment areas 141-148 the rigidity of the rim 121 is less and the deformation occurs to a greater extent. However, the greater deformation in the spoke attachment areas 141-142 is compensated by the residual inward deformation. In the wheel 133 with the tire 136 inflated, therefore, the distributed waving effect is reduced and, at best, is inexistent (as shown in FIG. 17d), whereas the localized waving effect in the jointing area 138 due to the joint is not compensated.

It should be noted that, starting from the condition shown in FIG. 17c, if the spokes 135 are loosened (or removed), the rim 121 shall have the same shape obtained with the previous process before the assembly of the spokes 135, i.e. that of FIG. 16b.

Localized Waving Effect Compensation on a Rim Made from Metallic Material

FIGS. 19 a and 19b show perspective views of a rim 221 and a wheel 233 according to a different embodiment.

The wheel 233 represented is a front wheel, of the type with equally distributed single spokes, and comprises the rim 221, a hub 234 and a set of spoke connections 235 between the hub 234 and spoke attachment areas 249 on the rim 221, alternating with intermediate areas 259. The rim 221 is of the metallic type, made through extrusion of a rod having a suitable cross section, calendering it and joining the ends at a jointing area 238. Therefore, FIGS. 4a to 4c are also representative of the section of the rim 221 and of the wheel 233, in circumferential areas different to the jointing area 238. Such FIGS. 4a to 4c thus also display the reference numerals of the wheel 233, in brackets.

In a position diametrically opposite the jointing area 238, a hole 237 is made in the rim 221 to house a valve for retaining air inside the tire 236 that can be associated with the outside of the rim 221.

The jointing in the area 238 is carried out by butt welding of the ends of the extruded and calendered rod. A pair of full metallic inserts 239, 240 (summarily shown in FIG. 19a) are inserted into the chamber 222 of the rim 221, used to allow the ends to be gripped with suitable pincers during welding without the risk of deforming the rim 221.

FIGS. 18 a to 18c refer to the rim 221 and to the wheel 233.

FIG. 18 a schematically shows a blank of the rim 221 after extrusion, calendering, joining in the jointing area 238, and after the braking races 231, 232 have been formed (for example by turning) on the outer sides 229, 230 of the wings 227, 228.

A deformation is made on the preform of FIG. 18a (for example with one of the processes described hereafter) so that, in the rim 221, the outer sides 229, 230 of the wings 227, 228 with the braking races 231, 232, are a greater distance Dg apart at the jointing area 238 than the distance D of the outer sides 229, 230 in the other areas (widening of the jointing area 238, FIG. 18b).

The distance in the axial direction between the outer sides 229, 230 varies progressively between the jointing area 238 and the adjacent areas, as shown by FIG. 18b.

When the wheel 233 is assembled using the rim 221, the spokes 235 are tightened between the rim 221 and the hub 234 and the tire 236 is mounted on the wheel 233 and inflated, there is an outward deformation of the wings 227, 228 with a uniform increase in the distance between the outer sides 229, 230 with the braking races 231, 232 along the entire circumference of the rim 221, except for the jointing area 238 in which the rigidity of the rim 221 is greater and the deformation occurs to a lower extent (FIG. 18c). However, such a lower deformation is compensated by the previous outward deformation. In the wheel 233 with the tire 236 inflated, therefore, the localized waving effect due to the jointing is reduced and, at best, is inexistent (as shown in FIG. 18c).

Distributed and Localized Waving Effect Compensation on a Rim Made From Metallic Material

FIGS. 20 a to 20d refer to a rim 321 and to a wheel 333 similar to the rim 121 and wheel 133 described above; in particular, the rim 221 is of the metallic type with a jointing area 338 and the wheel 333 has the same distribution of the spokes as the type described above.

Therefore, FIGS. 14 and 15 are also representative of the rim 321 and of the wheel 333. Such FIGS. thus also display the reference numerals of the wheel 333, in brackets. Moreover, FIGS. 4a to 4c are also representative of the section of the rim 321 and of the wheel 333, in circumferential areas different to the jointing area 338. FIGS. 4a to 4c thus also display the reference numerals of the wheel 333 in brackets.

A first deformation is made on the preform of FIG. 20a (for example with one of the processes described hereafter) so that, in the rim 321, the outer sides 329, 330 of the wings 327, 328 with the braking races 331, 332, are a shorter distance Da apart at the spoke attachment areas 341-348 than the distance Di of the outer sides 329, 330 with the braking races 331, 332 of the rim 321 at the intermediate areas 351-358. A second deformation is then made so that the outer sides 329, 330 of the wings 327, 328 of the rim 321 are a greater distance Dg apart at the jointing area 338 than the distance Di of the outer sides 329, 330 in the adjacent areas.

The distance in the axial direction between the outer sides 329, 330 varies progressively between the jointing area 338 and the adjacent areas and between the spoke attachment areas 341-348 and the intermediate areas 351-358, as shown by FIG. 20b.

When the wheel 333 is assembled using the rim 321 described and the spokes 335 are tightened between the rim 321 and the hub 334, the rim 321 and in particular the wings 327, 328 on which the braking races 331, 332 are formed, undergo a deformation for which reason the distance between the outer sides 329, 330 at the spoke attachment areas 341-348 increases, without however reaching the distance at the intermediate areas 351-358. The result is that shown in FIG. 20c.

When, finally, the tire 336 is mounted on the wheel 333 and inflated, there is an outward deformation of the wings 327, 328 with a non-uniform increase in the distance between the outer sides 329, 330 with the braking races 331, 332 along the circumference: in the jointing area 338 the rigidity of the rim 321 is greater and the deformation occurs to a lower extent, whereas in the spoke attachment areas 341-348 the rigidity of the rim 321 is less and the deformation occurs to a greater extent. However, the reduced deformation in the jointing area 338 is compensated by the previous outward deformation, as well as the greater deformation in the spoke attachment areas 341-348 is compensated by the residual inward deformation. In the wheel 333 with the tire 336 inflated, therefore, the localized waving effect in the jointing area 338 due to the joint and the distributed waving effect are reduced and, at best, are inexistent (as shown in FIG. 20d).

The distance between the outer sides 329, 330 of the wings 327, 328 with the braking races 331, 332 has smaller variations, and at best no variation, along the entire circumference of the wheel 333, including the jointing area 338.

In the wheel 333, therefore, the distributed waving and localized waving effects are compensated.

FIGS. 21 a-21d show a variant of the steps described in FIGS. 20a-20d for making the same wheel 333, in which first the spokes 335 are tightened and then the rim 321 is deformed. The spokes 335 are mounted on the preform (FIG. 21a) and tightened. The tightening, as stated, involves an outward deformation of the wings 327, 328 at the spoke attachment areas 341-348 (FIG. 21b). At this point a first deformation is carried out to deform the wings 327, 328 inwards at the spoke attachment areas 341-348 to obtain a shorter distance Da than the distance Di existing between the wings 327, 328 in the intermediate areas 351-358. Then follows a second outward deformation of the wings 327, 328 so that the outer sides 329, 330 with the braking races 331, 332 are a greater distance Dg apart at the jointing area 338 than the distances Da and Di of the outer sides 329, 330 in the other areas.

When, finally, the tire 336 is mounted on the wheel 333 and inflated, there is an outward deformation of the wings 327, 328 with a non-uniform increase in the distance between the outer sides 329, 330 with the braking races 331, 332 along the circumference: in the jointing area 338 the rigidity of the rim 321 is greater and the deformation occurs to a lower extent, whereas in the spoke attachment areas 341-348 the rigidity of the rim 321 is less and the deformation occurs to a greater extent. However, the lower deformation is compensated by the previous outward deformation, just as the greater deformation in the spoke attachment areas 341-348 is compensated by the residual inward deformation. In the wheel 333 with the tire 336 inflated, therefore, the localized waving effect due to the jointing 338 is reduced and, at best, is inexistent (FIG. 21d).

The distance between the outer sides 329, 330 of the wings 327, 328 with the braking races 331, 332 has smaller variations, and at best no variation, along the entire circumference of the wheel 333, including the jointing area 338.

It should be noted that, starting from the condition shown in FIG. 21d, if the tire 336 is deflated and the spokes 335 are loosened (or removed), the rim 321 shall have the same shape obtained with the previous process before the assembly of the spokes 335, i.e. that of FIG. 20b.

Localized Waving Effect Compensation on a Rim Made from Metallic Material: Dual Variant

For the described embodiments, it is possible to provide an alternative dual process of deformation of the rim. As an example hereafter the description of such an alternative is given for the wheel 233 (FIGS. 18a-18c), with reference to FIGS. 22a to 22c.

A deformation is carried out on such a preform of FIG. 22a (for example with one of the processes described hereafter, in particular the one illustrated in FIGS. 26a to 26d) so that, in the rim 221, the outer sides 229, 230 of the wings 227, 228 with the braking races 231, 232 of the rim 221 are a greater distance Dg apart at the jointing area 238 than the distance D of the outer sides 229, 230 in the other areas (similarly to what has been seen for FIGS. 18a-18c). In this case, however, instead of widening the jointing area 238, one starts from a preform with the outer sides 229, 230 of the wings 227, 228 at a greater distance equal to Dg (FIG. 22a) and the wings 227, 228 are narrowed to the distance D except for in the jointing area 238 (FIG. 22b). At this point the spokes 235 are mounted and tightened and the tire 236 is mounted and inflated (FIG. 22c) similarly to what has been seen with reference to FIG. 18c.

Processes for Making the Rim, with Compensation of the Flaring Effect

A rim like the rims shown and described above can be made in various ways so as to compensate the flaring effect.

In the case of a rim made from composite material, the shape of the rim (FIGS. 3a and 4a) with the wings converging is achieved directly in the molding step of the rim (for example using the process described in EP 1 231 077 and modifying the shape of the mold in accordance with the profile to be obtained).

In the case of a rim made from aluminum (or perhaps another metal), it is possible to make the extruded piece directly with the modified shape of the rim (FIGS. 3a and 4a).

Alternatively, again for rims made from metal and as shown in FIGS. 5a-6c and 6a-6c, it can be provided to start from an extruded piece with the wings of suitable section (increased), then machining the outer sides of the wings along the entire circumference (turning) so that they have the desired inclination.

Another alternative is to provide a standard extruded piece (for example the one shown in FIG. 2a) that is then inserted inside two suitably shaped half-molds S1 and S2, as schematically indicated in FIGS. 7a to 7d; the closing of the half-molds S1 and S2 determines the deformation of the wings along the entire circumference and therefore the desired shape of FIG. 7e (that corresponds to the rim of FIG. 4a).

Processes for the deformation of the wings to compensate the localized waving effect and the distributed waving effect

A possible process for obtaining a deformation of the wings, in this particular case an outward deformation, is described with reference to FIGS. 23a to 23d.

At the area to be widened (for example at the jointing 238 of the rim 221), the wing 228 is gripped between the ends of the arms P1 and P2 of a pincer P (FIG. 23b). The pincer P is rotated (FIG. 23c) in a controlled manner so that the wing 228 is deformed by a predetermined amount (for example 0.1 mm). The operation is repeated in an analogous way for the other wing 227. The final effect shall be a widening of the wings 227, 228, and therefore an increase in distance between the outer sides 229, 230, by 0.2 mm (FIG. 23d).

In a similar way, the deformation of the wings can be carried out inwards.

A first variant of such a process is described with reference to FIGS. 24a to 24d.

At the area to be widened (for example at the jointing 238 of the rim 221), the rim 221 is inserted in two half-molds S1 and S2. In the area located between the wings 227, 228 two punches S3 and S4 are inserted (FIG. 24b) that push the wings 227, 228 against the respective shaped walls of the half-molds S1 and S2 (FIG. 24c).

A second variant of such a process is described with reference to FIGS. 25a to 25e.

At the area to be widened (for example at the jointing 238 of the rim 221), a presser element PR in the form of a tapered toroidal slug (FIG. 25e) is pushed radially from the outside towards the centre of the rim 221 (FIG. 25c) to deform the wings 227, 228 outwards.

A process for obtaining a dual deformation of the wings, as provided in particular in the solution of FIGS. 22a-22c, is described with reference to FIGS. 26a to 26d.

At the jointing area 238, between the wings 227 and 228 an element of thickness SP is inserted to keep the jointing area 238 at the distance Dg (FIG. 19b). The rim 221 is then inserted into two half-molds S1, S2 that push the wings 227, 228 to the distance apart D for the entire circumference, except for the jointing area 238 where the element of thickness SP is located.

As stated above in the description of the various embodiments, at the moment of inflation of the tire the wings of the rim deform outwards causing them to move apart for the entire circumference of the rim and thus causing the braking races to move away. Such a flaring effect and its compensation have been described in greater detail for the wheels 3 and 33, with reference to FIGS. 3 to 7.

It should be noted that each of the compensations of the flaring, distributed waving and localized waving effects (where necessary, i.e. with metallic rims with jointing) can be implemented alone or with one or more of the others on the same rim.

As an example, in the previous description of the wheel 3 the compensation of the flaring effect has been illustrated, but there could also be a compensation of the distributed waving effect and/or (if the rim 1 is metallic) of the localized waving effect. For the wheel 133 the compensation of the distributed waving effect has been illustrated, but not of the localized waving effect and of the flaring effect, which are still present since the rim 121 is made from metal, with jointing. For the wheel 233 the compensation of the localized waving effect has been illustrated, but not of the distributed waving effect and of the flaring effect, which are still present since the rim 221 is made from metal, with jointing. For the wheel 333 the compensation both of the distributed waving effect and of the localized waving effect have been illustrated.

Furthermore, it should be noted that the previous description of wheels with compensation of the distributed and localized waving effects (wheels 33, 133, 233 and 333) has been made with reference in particular to rims with a section with an inverted A-shaped configuration, since the U-shaped configuration is not very widely used. It is clear, however, that the compensation of the distributed and/or localized waving effects in such rims shall be carried out in a similar way to what has been seen above, taking into consideration that the compensation of the distributed waving effect must provide for a widening of the respective spoke attachment areas with respect to the intermediate areas and not for a narrowing, as described for the inverted A-shaped configuration.

On the other hand, in the case of rims with a more complex section than those with an inverted A-shape (rims with many chambers), the behavior with respect to the distributed waving effect is the same as the rims with an inverted A-shaped section, and therefore what has been described above also applies directly to such rims.

Claims

1. Rim, suitable for being coupled with a hub to form a bicycle wheel comprising a pair of wings connected by at least one bridge, wherein the wings converge.

2. Rim according to claim 1, wherein each wing has an outer side with a braking race.

3. Rim according to claim 1, wherein the rim comprises a plurality of spoke attachment areas, alternating in a circumferential direction with a plurality of intermediate areas in the at least one bridge, and wherein an axial distance between the wings at the spoke attachment areas is different to an axial distance between the wings at the intermediate areas.

4. Rim according to claim 1, comprising a single bridge between the pair of wings, and wherein an axial distance between the wings at the spoke attachment areas is greater than an axial distance between the wings at the intermediate areas.

5. Rim according to claim 1, comprising a lower bridge and at least one upper bridge between the pair of wings, wherein an axial distance between the wings at the spoke attachment areas is smaller than an axial distance between the wings at the intermediate areas.

6. Rim according to one of claim 1, wherein an axial distance between the wings is measured between outer sides thereof.

7. Rim according to claim 1, made from metal from a blank that is extruded, calendared into circular shape and closed upon itself through jointing between ends of the blank at a jointing area, wherein an axial distance between the wings at the jointing area is greater than an axial distance between the wings at areas remote from the jointing area.

8. Rim according to claim 6, made from a blank that is jointing between ends of the blank at a jointing area, wherein the axial distance between the wings at the jointing area is greater than the axial distance between the wings at the spoke attachment areas as well as the axial distance between the wings at the intermediate areas.

9. Rim according to claim 7, made from a blank that is jointing between ends of the blank at a jointing area, wherein the axial distance between the wings at the jointing area is greater than the axial distance between the wings at the spoke attachment areas as well as the axial distance between the wings at the intermediate areas.

10. Bicycle wheel, comprising a hub, a rim and a plurality of spokes for connection of the rim to the hub, wherein the rim comprises a pair of wings for holding a tire connected by at least one bridge, wherein when the tire is dismounted from the wheel or else—if the tire is mounted and underinflated—the wings converge.

11. Bicycle wheel according to claim 10, wherein, when the tire is mounted on the wheel and is inflated, the wings converge less.

12. Bicycle wheel according to claim 10, wherein, when the tire is mounted on the wheel and is inflated, the wings are parallel.

13. Bicycle wheel according to claim 10, wherein the rim comprises a plurality of spoke attachment areas, alternating in a circumferential direction with a plurality of intermediate areas in the at least one bridge, and wherein in the rim, before connection to the hub through the spokes, an axial distance between the wings at the spoke attachment areas is different to an axial distance between the wings at the intermediate areas.

14. Bicycle wheel according to claim 10, wherein the rim is made from metal from a blank that is extruded, shaped into circular shape and closed upon itself through application of a joint between ends of the blank, in which, when the tire is dismounted from the wheel or else—if the tire is mounted and underinflated—the axial distance between the wings at the joint is greater than the axial distance between the wings at areas remote from the joint.

15. Bicycle wheel according to claim 14, wherein, when the tire is mounted on the wheel and is inflated, the variation in axial distance between the wings at the joint and at the areas far from the joint is less than the variation in axial distance between the wings at the joint and at areas remote from the joint with the tire deflated.

16. Process for making a rim, having a circumference, suitable for being mounted in a bicycle wheel, comprising the step of: a) providing a pair of wings connected by at least one bridge, wherein in step a) the wings are formed converging.

17. Process according to claim 16, comprising the step of: b) providing a plurality of spoke attachment areas and a plurality of intermediate areas, alternating in a circumferential direction, in the at least one bridge;wherein in step a) it is provided that the wings be shaped and sized so that an axial distance between the wings at the spoke attachment areas is different to an axial distance between the wings at the intermediate areas.

18. Process according to claim 17, wherein step a) comprises the substeps of: a′) forming the rim with the wings spaced apart uniformly along the entire circumference;a″) deforming the wings varying the distance between them at the spoke attachment areas and/or at the intermediate areas.

19. Process according to claim 18, wherein step a″) comprises bending the wings inwards and/or outwards at the spoke attachment areas and/or at the intermediate areas.

20. Process according to claim 18, wherein step a″) comprises removing material from outer sides of the wings at the spoke attachment areas and/or at the intermediate areas.

21. Process according to claim 17, wherein step a) provides for forming the rim directly with the wings spaced apart non-uniformly along the circumference.

22. Process according to claim 16, wherein the rim is made from metal from a blank that is extruded, shaped into circular shape and closed upon itself through jointing between ends of the blank to form a jointing area, also comprising the steps of: c) deforming the wings so that an axial distance between the wings at the jointing area is greater than an axial distance between the wings at areas remote from the jointing area.

23. Process for making a bicycle wheel, comprising the steps of: a) making a rim having a circumference and comprising a pair of wings connected by at least one bridge;b) connecting the rim with a hub through spokes or arms;wherein in step a) the wings are formed converging.

24. Process according to claim 23, comprising the steps of: c) mounting a tire on the rim;d) inflating the tire mounted on the rim to a predetermined inflation pressure, so that the wings are parallel.

25. Process according to claim 23, comprising the steps of: e) providing a plurality of spoke attachment areas and a plurality of intermediate areas, alternating in a circumferential direction, in the at least one bridge; wherein in step b) the spokes are tightened between the hub and the spoke attachment areas of the at least one bridge;and wherein in step a) it is provided that the wings are shaped and sized so that before the spokes are tightened an axial distance between the wings at the spoke attachment areas is different to an axial distance between the wings at the intermediate areas.

26. Process according to claim 25, wherein step a) comprises the substeps of: a′) forming the rim with the wings spaced apart uniformly along the entire circumference;a″) deforming the wings varying the distance between them at the spoke attachment areas and/or at the intermediate areas.

27. Process according to claim 26, wherein step a″) comprises bending the wings inwards and/or outwards at the spoke attachment areas and/or at the intermediate areas.

28. Process according to claim 26, wherein step a″) comprises removing material from outer sides of the wings at the spoke attachment areas and/or at the intermediate areas.

29. Process according to claim 25, wherein step a) provides for forming the rim directly with the wings spaced apart non-uniformly along the circumference.

30. Process according to claim 24, wherein the rim is made from metal from a blank that is extruded, shaped into circular shape and closed upon itself through jointing between ends of the blank at a jointing area, also comprising the steps of: f) deforming the wings so that an axial distance between the wings at the jointing area is greater than an axial distance between the wings at areas remote from the jointing area;wherein in step d), the tire mounted on the rim is inflated to the predetermined inflation pressure, so that the axial distance between the wings at the jointing area is equal to the axial distance between the wings at the areas remote from the jointing area.

31. A bicycle wheel comprising a rim coupled to a hub, the rim comprising a bridge between sidewalls and a pair of wings that converge at least some areas around a circumference of the rim.

32. The bicycle wheel of claim 31, wherein an outer side of the sidewalls comprises a braking race.

33. A process for making a bicycle wheel rim comprising providing a pair of converging wings connected by a bridge.

34. A bicycle wheel comprising: a hub;a rim connected to the hub through a plurality of spokes, the rim comprising: a pair of wings that mate with a rim;a bridge that spans sidewalls that have the wings at a terminal end thereof; wherein the wings converge to a predetermined convergence angle at least some areas around a circumference of the rim before a tire is inflated.

35. The wheel of claim 33, wherein the wings are parallel after a tire mounted on the rim is inflated.

36. The bicycle wheel of claim 33, wherein an outer side of the sidewalls comprises a braking race.

37. Process for making a bicycle wheel, comprising the steps of: a) making a rim having a circumference and comprising a pair of wings connected by at least one bridge; andb) connecting the rim with a hub through spokes or arms;wherein in step a) the wings are formed converging.

38. A bicycle wheel comprising a hub,a rim; anda plurality of spokes extending between the hub and the rim,the rim further comprising a pair of wings suitable for holding a tire,a bridge connecting the wingswherein the wings converge to a first predetermined convergence angle when the tire is deflated.

39. The bicycle wheel according to claim 38, wherein the wings converge to a second predetermined convergence angle when the tire is mounted on the wheel and inflated, the second angle being less than the first angle.

40. The bicycle wheel according to claim 38, wherein the wings are parallel when the tire is mounted on the wheel and is inflated.