权利要求：
Claims
1. Method of assembling a bicycle rim (12), the method comprising the steps
of:
providing one or more patterns (48, 50) of removable material (M), said one
or more patterns (48, 50) together having an outer shape resembling an in-
ner shape of at least part of said rim (12);
covering at least some of the outer sides of said one or more patterns (48,
50) of removable material (M) with one or more layers of webs of fiber ma-
terial (52, 54, 56); said one or more layers of webs of fiber material (52, 54,
56) forming said rim (12);
placing said covered one or more patterns (48, 50) of removable material
(M) into a mold (42), said mold (42) having an internal cavity (42') the inter-
nal cavity (42') corresponding to an outer shape of said rim (12);
heating said mold (42) to a first temperature in a first temperature range.
2. Method of assembling a bicycle rim (12) according to claim 1, wherein at
least one of the one or more patterns (48, 50) is formed by three, four, five
or more pattern segments (50', 48’) that are assembled to form the at least
one of the one or more patterns (48, 50).
3. Method of assembling a bicycle rim (12) according to claim 2, wherein said
pattern segments are covered with one or more layers of webs of fiber ma-
terial (52, 54, 56) before or after the pattern segments are combined to form
said pattern.
4, Method of assembling a bicycle rim (12) according to at least one of the
preceding claims, wherein at least one of the one or more patterns (48, 50)
comprises one or more first inserts (38’) integrally formed therein.
5. Method of assembling a bicycle rim (12) according to claim 3, wherein at
least one of said first inserts (38’) is configured to interact with a support
apparatus (64) used to assemble the rim (12).
6. Method of assembling a bicycle rim (12) according to one of the preceding
claims,
wherein said bicycle rim (12) has one or more internal spaces (22', 24’),
with each internal space (22', 24") being formed by first and second patterns
(50, 48), with at least one of the first and second patterns (50, 48) being
formed by three, four, five or more pattern segments (50', 48') that are as-
sembled to form the pattern (48, 50) of the respective internal space (22',
24') prior to covering the respective patterns (48, 50) forming the internal
space (22', 24') with said one or more layers of webs of fiber material (52,
54, 56).
7. Method of assembling a bicycle rim (12) according to claim 6,
wherein said bicycle rim (12) has first and second internal spaces (24’, 22°)
that are formed by respective first and second patterns (50, 48), with the
first pattern (50, 48) forming said first internal space (24') and being covered
with said one or more layers of webs of fiber material (54) and sequentially
assembling said second pattern (48, 50) from respective second pattern
segments (48', 50’) at said covered first pattern (50, 48) from two, three,
four, five or more second pattern segments (48', 50’) to form said second
pattern (48, 50) covered with one or more further layers of webs of fiber ma-
terial (52, 56).
8. Method of assembling a bicycle rim (12) according to claim 7, wherein said
first pattern is also formed from two, three, four, five or more first pattern
segments (50') to form said first pattern (50).
9. Method of assembling a bicycle rim (12) according to claim 7 or claim 8,
wherein said combined first and second patterns (50, 48) are covered with
one or more further layers of webs of fiber material (56).
10. Method of assembling a bicycle rim (12) according to one of the preceding
claims,
further comprising the step of heating said mold (42) to a second tempera-
ture in a second temperature range.
11. Method of assembling a bicycle rim (12) according to to one of the preced-
ing claims,
further comprising the step of heating said mold (42) to a third temperature
in a third temperature range.
12. Method of assembling a bicycle rim (12) according to claim 10 or claim 11,
wherein said first temperature is lower than said second temperature.
13. Method of assembling a bicycle rim (12) according to claim 11 or claim 12,
wherein said second temperature is lower than said third temperature.
14. Method of assembling a bicycle rim (12) according to one of the preceding
claims,
wherein a vacuum is applied to said mold (42) during and/or prior to heating
said mold (42) to said first temperature range, optionally during and/or prior
to heating said mold (42) to said second and third temperature ranges.
15. Method of assembling a bicycle rim (12) according to claim 14,
wherein said vacuum is selected with a pressure in the range of 0.8 to 10
bar.
16. Method of assembling a bicycle rim (12) according to one of the preceding
claims,
further comprising the step of:
introducing a resin (R) into said mold (42) prior to and/or during said step of
heating of said mold (42) to said first temperature.
17. Method of assembling a bicycle rim (12) according to claim 16,
further comprising the step of:
curing said resin (R) in said mold (42), wherein said step of curing compris-
es at least one of the application of heat and UV light.
18. Method of assembling a bicycle rim (12) according to any one of claim 16 or
claim 17 when directly or indirectly dependent on claim 10,
wherein said step of the application of heat comprises heating said mold
(42) to said second temperature and/or heating said resin (R) on introduc-
tion into said mold (42).
19. Method of assembling a bicycle rim (12) according to one of claims 16 to
18,
wherein said resin (R) is heated to below a curing temperature of said resin
(R) on the introduction of said resin (R) into said mold (42).
20. Method of assembling a bicycle rim (12) according to one of claims 16 to
19,
wherein said resin (R) is one of a one-component resin (R), a two-
component resin (R) comprising a hardener, and a multi-component resin
comprising one or several hardeners.
21. Method of assembling a bicycle rim (12) according to one of claims 16 to
20,
wherein the resin (R) comprises a resin (R) on an epoxy basis, a resin (R)
on a polyurethane basis, a resin (R) on a cyanate ester basis or another
basis suitable for injection or infusion.
22. Method of assembling a bicycle rim (12) according to one of the preceding
claims,
wherein said one or more patterns (48, 50) comprise at least one of one or
more recesses (74) and projections (70) in an outer surface thereof.
23. Method of assembling a bicycle rim (12) according to one of the preceding
claims,
wherein said one or more patterns (48, 50) of removable material (M) are
made of wax.
24. Method of assembling a bicycle rim (12) according to one of the preceding
claims,
wherein said one or more patterns (48, 50) of removable material (M) are
produced in a 3D printing process, an injection molding process and a wax
casting process.
25. Method of assembling a bicycle rim (12) according to claim 24, wherein said
wax casting process comprises the steps of:
providing a wax mold (58) having an inner space (58') having a shape cor-
responding to an outer shape of said pattern (48, 50);
introducing said removable material (M) into said inner space (58') of said
wax mold (58) in liquid form; wherein said step of introducing said remova-
ble material (M) into said wax mold (58) comprises filling between 40 and
99% of said inner space (58') of the wax mold (58) with liquid removable
material (M);
introducing gas (G) into said liquid removable material (M) present in said
wax mold (58) and pressurizing said removable material (M) present in said
wax mold (58) with a pressure difference between an outside of said formed
wax pattern (48, 50) and a hollow space within said wax pattern (48, 50) se-
lected in the range of 0.02 to 20 bar;
moving said wax mold (58) to completely coat an inner surface (58") of said
wax mold (58) with said liquid removable material (M); and
solidifying the removable material (M) in said wax mold (58).
26. Method of assembling a bicycle rim (12) according to one of the preceding
claims,
wherein said one or more patterns (48, 50) of removable material (M) have
a melting point selected in the temperature range of 80 to 140°C, preferably
in the range of 95 to 120°C.
27. Method of assembling a bicycle rim (12) according to one of the preceding
claims,
wherein said one or more patterns (48, 50) of removable material (M) re-
main stable in shape to temperatures selected in the range of 60 to 100°C,
preferably in the range of 70 to 95°C.
28. Method of assembling a bicycle rim (12) according to one of the preceding
claims,
wherein said one or more patterns (48, 50) of removable material (M) re-
main stable in shape at temperatures below a melting point of said remova-
ble material (M).
29. Method of assembling a bicycle rim (12) according to one of the preceding
claims,
wherein said one or more patterns (48, 50) each have one or more second
inserts (38) present therein, with said second inserts being fixedly attached
to said bicycle rim (12).
30. Method of assembling a bicycle rim (12) according to claim 29,
wherein said second inserts (38) are provided at positions for spokes (16) of
said rim (12) and/or at a position of a valve associated with a wheel (10)
formed by said rim (12).
31. Method of assembling a bicycle rim (12) according to claim 29 or claim 30
when directly or indirectly dependent on claim 4,
wherein said second inserts (38) are directly or indirectly attached to said
first inserts (38).
32. Method of assembling a bicycle rim (12) according to one of the preceding
claims,
wherein said one or more layers of fiber material and/or further layers of
webs of material (52, 54, 56) comprise carbon fibers, glass fibers, basalt fi-
bers, wood fibers, hemp fibers, aramid fibers, and polyester fibers, respec-
tively in dry condition or as a prepreg.
33. Method of assembling a bicycle rim (12) according to one of the preceding
claims,
wherein at least one of said one or more patterns (48, 50) is supported at a
respective support apparatus (64).
34. A bicycle rim (12), in particular obtainable by a method in accordance with
one of the preceding claims, said bicycle rim (12) being formed of compo-
site material, said bicycle rim (12) having one or more internal spaces (22',
24") formed by walls (18, 26), with a wall thickness of said walls (18, 26) of
said bicycle rim (12) having a predefinable wall thickness with a tolerance of
the wall thickness lying in the range of + 0.5 mm, in particular of £ 0.1 mm,
especially of + 0.05 mm, for a wall thickness selected in the range of 1 to 4
mm, in particular for a length of material of said bicycle rim (12) cut from
said rim in the range of 1 to 5 mm and at a width selected in the range of
05t02.5cm.
35. The bicycle rim (12) according to claim 34, wherein said bicycle rim (12) has
a tolerance of the wall thickness lying in the range of £ 0.3 mm, especially
of £0.2 mm, for a wall thickness selected in the range of 1 to 4 mm.
36. The bicycle rim (12) according to claim 34 or claim 35, wherein said bicycle
rim (12) has a void content of less than 2%, in particular of less than 1.5%. .
37. The bicycle rim (12) according to one of claims 34 to 36, wherein said bicy-
cle rim (12) has a tolerance of the surface profile of + 0.1 mm.
38. The bicycle rim (12) according to one of claims 34 to 37, wherein said bicy-
cle rim (12) has a tolerance of the surface profile of £ 0.05 mm, in particular
of £0.03 mm, especially of £0.01 mm.
39. The bicycle rim (12) according to one of claims 34 to 38, wherein said bicy-
cle rim comprises reinforcing ribs (34), reinforcing beads, stiffening corruga-
tions and/or reinforcing platforms (36) formed at at least part of an inner sur-
face (34) of said bicycle rim (12).
40. The bicycle rim (12) according to one of claims 34 to 39, wherein said bicy-
cle rim (12) comprises inserts (38) present at positions of said bicycle rim
(12) corresponding to positions of spokes (16) and/or of a valve associated
with a wheel (10) formed by said rim (12).
41. The rim (12) according to one of claims 34 to 40, wherein said bicycle rim
(12) comprises apertures (40, 72) inherently present in at least one wall (18,
26) of the bicycle rim (12).