Method for producing composite bicycle rim

1. A method for making a bicycle rim comprising the steps of:

a) providing a mold shaped for forming the bicycle rim, at least one first element for forming walls that define at least one radially inner circumferential chamber and at least one second element for forming walls that include tire coupling wings;

b) providing at least one reinforcement element including unidirectional structural fibers;

c) arranging a composite material having structural fibers incorporated in a polymeric material in the mold about the at least one first element and partially about the at least one second element;

d) arranging the at least one reinforcement element circumferentially in a space defined at an intersection of the walls, such that the unidirectional structural fibers extend substantially parallel to a circumferential direction of the bicycle rim;

e) subjecting the mold, the at least one first element and the at least one second element to a pressure and temperature sufficient to cause curing of the polymeric material, formation of the at least one reinforcement element to complement the space defined at the intersection of the walls, and formation of a molded bicycle rim within the mold;

f) removing the molded bicycle rim from the mold; and

g) removing the at least one second element from the molded bicycle rim.

2. The method according to claim 1 wherein step b) comprises the substeps of:

b1) providing a band of unidirectional structural fibers incorporated in a polymeric material; and

b2) spirally winding the band upon itself around an axis extending parallel to the structural fibers.

3. The method according to claim 2 , wherein step b) further comprises the substep of:

b3) associating a film of gluing substance with the band.

4. The method according to claim 2 wherein step b) further comprises the substep of:

b3) winding containment means non-continuously around an outer surface of the at least one reinforcement element.

5. The method of claim 1 wherein step d) comprises arranging at least one portion of the at least one reinforcement element circumferentially in the space, partially overlapping adjacent ends of the at least one portion.

6. The method of claim 1 , wherein step d) comprises arranging at least one portion of each one of the reinforcement elements circumferentially in a respective space, such that a position of adjacent ends of the at least one portion of a first one of the reinforcement elements in a first space is circumferentially staggered with respect to a position of adjacent ends of the at least one portion of a second one of the reinforcement elements in a second space.

7. The method of claim 1 wherein the step c) comprises the substeps of:

c1) arranging a first and a second layer of at least one ply of structural fibers incorporated in a polymeric material in the mold;

c2) arranging the at least one first element over the first and second layer;

c3) folding the second layer over the at least one first element;

c4) arranging the at least one second element over the second layer; and

c5) folding the first layer over the at least one second element.

8. The method of claim 1 wherein step c) comprises the substeps of:

c1) arranging a first layer of at least one ply of structural fibers incorporated in a polymeric material in the mold;

c2) arranging the at least one first element over the first layer;

c3) arranging a second layer of at least one ply of structural fibers incorporated in a polymeric material over the at least one first element;

c4) arranging the at least one second element over the second layer; and

c5) folding the first and second layers over the at least one second element.

9. The method of claim 1 wherein the step c) comprises the substeps of:

c1) arranging a first and a second layer of at least one ply of structural fibers incorporated in a polymeric material in the mold;

c2) arranging the at least one first element over the first and second layers;

c3) folding the second layer over the at least one first element;

c4) arranging a third layer of at least one ply of structural fibers incorporated in a polymeric material over the second layer;

c5) arranging the at least one second element over the second layer; and

c6) folding the first and third layers over the at least one second element.

10. The method of claim 1 wherein step c) further comprises the substep of arranging an additional layer of structural fibers incorporated in a polymeric material at a spoke attachment zone of the bicycle rim.

11. The method of claim 1 wherein the structural fibers are woven, and include weft and warp directions that form an angle of substantially 45° with respect to a circumferential direction of the bicycle rim.

12. The method of claim 1 wherein the at least one first element is an inflatable bag.

13. The method of claim 1 further comprising the step of removing the at least one first element from the bicycle rim.

14. A method for making a bicycle rim comprising the steps of:

a) providing a mold shaped for forming the bicycle rim;

b) providing at least one first element for forming walls that define a radially inner circumferential chamber and at least one second element for forming walls that include tire coupling wings;

c) providing at least one reinforcement element including unidirectional structural fibers;

c1) embedding the unidirectional structural fibers of the at least one reinforcement element in a gluing substance that hinders sliding;

d) arranging a composite material having structural fibers incorporated in a polymeric material that is different from the gluing substance in the mold about the at least one first element and partially about the at least one second element;

e) arranging the at least one reinforcement element in a space defined at an intersection of the walls;

f) subjecting the mold to a pressure and temperature sufficient to cause curing of the polymeric material and formation of a molded bicycle rim within the mold;

g) removing the molded bicycle rim from the mold; and

h) removing the at least one second element from the molded bicycle rim.

15. The method of claim 14 wherein in step f), the at least one second element expands diametrically under application of heat.

16. The method of claim 14 wherein the at least one first element is an inflatable bag.

17. The method according to claim 14 wherein step c) further comprises the substeps of:

c2) providing a band of unidirectional structural fibers incorporated in a polymeric material; and

c3) spirally winding the band upon itself around an axis parallel to the direction of the structural fibers.

18. The method according to claim 17 , wherein step c) further comprises the substep of:

c4) associating a film of the gluing substance with the band.

19. The method according to claim 17 wherein step c) further comprises the substep of:

c4) winding containment means non-continuously around an outer surface of the at least one reinforcement element.