Compression molded hub shell
An apparatus including a hub shell. The hub shell can include a hub body; a first spoke flange; and a second spoke flange. The first spoke flange and the a second spoke flange can include a fiber reinforced plastic. The fiber reinforced plastic can include fibers having a range of lengths between 0.2 and 3 inches.
1. An apparatus, comprising:
a hub shell comprising:
a hub body;
a first spoke flange; and
a second spoke flange;
wherein:
at least the first spoke flange and the second spoke flange comprise a fiber reinforced plastic; and
the fiber reinforced plastic include fibers having a range of lengths between 0.2 and 3 inches;
wherein:
the second spoke flange comprise spoke holes;
a bundle of continuous unidirectional fibers surround each of the spoke holes;
the bundles of continuous unidirectional fibers are embedded in the fiber reinforced plastic including the fibers having the range of lengths between 0.2 and 3 inches;
the second spoke flange comprises a first set of ribs on a drive side of the second spoke flange; and
each rib of the first set of ribs is curved and comprises a first inner portion and a second outer portion such that a first spoke hole of the spoke holes located in the first inner portion is at a first angle and a second spoke hole of the spoke holes located in the second outer portion is at a second angle.
2. The apparatus of claim 1 , wherein the fibers have an average length of about 2 inches.
3. The apparatus of claim 1 , wherein a radius of the second spoke flange is about twice a radius of the hub body.
4. The apparatus of claim 1 , wherein the first spoke flange comprises spoke holes.
5. The apparatus of claim 1 , wherein the second spoke flange comprises a second set of ribs on a non-drive side of the second spoke flange.
6. The apparatus of claim 1 , wherein the first set of ribs comprise spoke holes, and the spoke holes are perpendicular to an axis of the hub shell.
7. The apparatus of claim 1 , wherein the second spoke flange is formed by compression molding.
8. The apparatus of claim 1 , wherein the hub body comprises fiber reinforced plastic include fibers having a range of lengths between 0.2 and 3 inches.
9. The apparatus of claim 1 , further comprising a bearing seat formed to accept a bearing without further machining, where the bearing seat has a tolerance of 0.5 mm or less.
10. The apparatus of claim 1 , further comprising at least one of annular, axial, and radial fiber reinforcements.
11. The apparatus of claim 10 , wherein the fiber reinforcements comprise unidirectional fiber.