Methods for Fabricating Thermoplastic-based Composite Spokes and Spoke Assemblies
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United States of America
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Feb 20, 2025
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Aug 13, 2024
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Aug 13, 2024
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Abstract
A method for fabricating thermoplastic bicycle spokes that securely couple to an end fitting, at one or both ends thereof, via a non-threaded, mechanical interlocking geometry. A spoke body is fabricated from thermoplastic resin, and then thermoplastic material is added, in situ (using the internal geometry of the end fitting as a form). This increases the effective diameter of the spoke at at least one end thereof to create an engagement feature that is adapted to interlock with the internal configuration of the end fitting. Additionally, by virtue of the method, the end of the spoke has a desirable fiber alignment, wherein the fibers substantially align with in-use loads.
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