Vehicle wheel spoke connection

A vehicle wheel, comprising a rim, a hub, a plurality of spokes extending between the rim and hub, a bracing element including a hole with a central axis, a sidewall, a longitudinally inward entrance, and at least one of an engagement surface and an engagement edge outward of the entrance, a connecting element comprising a multiplicity of discreet segments. The bracing element comprises at least a portion of one of the rim and hub. At least one segment includes a laterally projecting overhanging surface. The first segment is positioned within the hole, with the overhang surface overlying one of the engagement surface and engagement edge in an overlie engagement. The second segment is positioned within the hole to include an opening between the first and second segments. The spoke is positioned within the opening and is connected to the connecting element with the overlie engagement to support spoke tensile load.

BACKGROUND OF THE INVENTION

(1) Field of the Invention

This invention is related to the means of attachment between the spoke and the rim of a vehicle wheel and between the spoke and the hub of a vehicle wheel. This invention is particularly related to the connection of a spoke with a rim structure having a “double-wall” construction with an unpierced tire bed wall for tubeless tire applications.

(2) Description of the Related Art

Bicycle wheel rims have historically been constructed to accept pneumatic tires that are designed to work in conjunction with an inner tube. This is the standard of the industry and is the arrangement that we are all familiar with. In such a prior art configuration, the rim's tire bed includes a through-hole that is drilled through for passage of the spoke nipple. In a rim of “single-wall” construction, the tire bed and the spoke bed are shared such that the spoke nipple bears directly against the rim's tire bed. In a rim of “double-wall” construction, the rim has two lateral walls, a tire bed wall and a spoke bed wall, usually with a radial gap or cavity therebetween. The rim is drilled through both walls, piercing both the tire bed and the spoke bed walls, with the spoke bed recessed below the tire bed to accept the spoke nipples. Generally, the spoke is presented through the spoke bed from the inside diameter of the rim and the spoke nipple is presented for attachment to the spoke through the tire bed and from the outside diameter of the rim. With single-wall or double-wall rim constructions, a rim strip is utilized to protect the inner tube from the sharp edges associated with the holes in the tire bed wall and/or with the spoke nipples. With rims of double-wall construction, the rim strip also serves to prevent the inner tube from extruding through the drilled access openings in the tire bed.

With the recent advent of tubeless tire technology, where the conventional inner tube is eliminated and the tire's beads are sealed directly against the rim, it is desirable that the tire bed wall be sealed and airtight to prevent air leakage from the tire cavity. This typically involves a rim of double-wall construction where the tire bed is sealed while the spoke bed is then adapted to accept the spokes. One preferable method for sealing the tire bed is to eliminate the aforementioned spoke access holes in the tire bed. If the tire bed is not pierced for the spokes, then the only hole through the tire bed will be for the tire inflation valve, which may be constructed of rubber and is relatively easy to seal against the tire bed. An example of such a tubeless arrangement is outlined by Lacombe et al. in U.S. Pat. No. 6,443,533, where the tire bed remains unpierced and the spoke bed includes extruded spoke holes that are directly threaded with internal threads to accept special externally threaded spoke nipples.

Reference is also made to prior art UK Patent Application GB2479870A by Jonathan Thulbon. Thulbon shows his spoke (3) connected to his rim (4) by eyelets (7). This eyelet is a one-piece element with slots (74) to provide flexure for installation with his rim. Thulbon's arrangement has several shortcomings: Firstly, the fact that his single-piece eyelet must flex for installation requires that the material of his eyelet be of relatively flexible and ductile material, such as unreinforced plastic. However, such material generally has low strength in comparison to stronger materials that are more rigid and less ductile, such as metals or fiber-reinforced plastics that would not be able to flex as Thurbon requires. Since spoke tension forces exert a very high stress at its connection to the rim, the weaker material of the Thulbon eyelet results in a relatively weak spoke connection that may also be more prone to flex and creep. Second, since Thulbon's eyelet is of one-piece design, the entire eyelet must be inserted at one time. This simultaneous installation, as well as accommodation for his flexure, places severe geometry restriction on his eyelet. As such, Thulbon's design is limited to a relatively shallow depth of lateral overlap and engagement between his eyelet and his rim, thus increasing stresses at this interface and further weakening his spoke connection. Thirdly, the overlie engagement between Thulbon's spoke nipple and eyelet is located inwardly from the outboard surface of his spoke bed, which requires that his eyelet include longitudinally outward extension portions that surround the head of his nipple to engage his rim. These extension portions require that the corresponding hole in his rim be significantly larger than the head of his spoke nipple. This oversized hole serves to further weaken his rim in this highly-loaded area. Fourthly, these extension portions also serve to laterally offset the overlie engagement between his rim and eyelet from the overlie engagement between his eyelet and nipple. This offset places additional tensile and bending stress on the eyelet due to spoke tension forces, further weakening his spoke connection. Fifthly, Thulbon does not contemplate a longitudinal engagement between his spoke and eyelet and instead utilizes only a single overlie engagement at a single longitudinal location. Such a single overlie engagement requires a very large laterally projected area of overlie to resist spoke tension loads, which results in a larger eyelet and a correspondingly larger hole in his rim.

SUMMARY OF THE INVENTION

The present invention utilizes an expandable connecting element or ferrule that may be blindly installed through a hole in the spoke bed. The connecting element is expanded to engage the edge and/or adjacent surface at the distal end of the hole. The spoke, or an intermediate element connected to the spoke, is engaged to the connecting element to create a firm connection between the spoke and the spoke bed. It is noted that the spoke bed constitutes a portion of the rim or hub flange to which the connecting element is attached. The novelty of such a blind connection of the spoke is particularly advantageous in conjunction with rims associated with tubeless tires.

It is an object of the present invention to create a spoke connection: that may be blindly installed with the spoke bed of the rim and/or hub: that may leave the tire bed of the rim to remain unpierced; that may eliminate the necessity of a rim strip; that may permit a spoke connection that may otherwise be geometrically impossible by conventional means; and that may result in a robust connection capable of resisting spoke tension loads.

One aspect of the invention involves a method for assembling a wheel. For each of a number of spoke holes in the wheel rim, a multi-piece connecting element associated with a given spoke is inserted radially outward through the spoke hole in the spoke bed of the rim (or radially inwardly for a spoke bed associated with a hub). The multiple discreet pieces (i.e. segments) of the connecting element may spread relative to each other or otherwise laterally shifted to effectively expand and engage the edge or surface adjacent the distal end of the hole. A spoke is then connected to the connecting element, either directly or by means of an intermediate connecting element. This connection between spoke and connecting element preferably includes an overlie engagement and/or a longitudinal engagement and/or an integral joinder.

In various implementations, the connecting element may or may not include a flange, the connecting element may be keyed to the hole, the connecting element may be keyed to the spoke bed surface, the connecting element's opening axis may be parallel to the hole's axis or the opening's axis may be at an angle to the hole's axis, the connector may have an unthreaded, fully threaded, or a partially threaded opening, the connecting element may include an extension.

Another aspect of the invention involves a wheel. The wheel has an outer rim with a spoke bed wall having spoke holes and preferably a tire bed radially outboard of the spoke bed wall and lacking holes aligned with the spoke holes. Spokes couple the rim to the hub with connecting elements coupling the spokes to the rim. Each connecting element has a first portion (i.e. collar portion) extending within an associated spoke hole. An opening of each connecting element accommodates either an associated spoke or an intermediate element coupled to the associated spoke. The connecting element has a second portion (i.e. enlarged portion) radially outboard of the spoke bed and cooperating with an outboard surface of the spoke bed to prevent radially inward movement of the associated spoke and permitting tension in the spoke to be transferred to the rim. In various implementations, the connecting element may consist essentially of a multiplicity of discreet segments. The spoke or an intermediate element coupled to the spoke may have an overlie engagement with the connecting element. The spoke, or an intermediate element connected to the spoke, may serve to maintain the connecting element in its open or expanded orientation and thus maintain its engagement with the spoke bed wall. As disclosed herein, the connecting element may also be utilized to connect the spoke to a spoke bed of the hub shell in a manner similar to that described above.

Another aspect of the invention involves a wheel rim. The rim has a spoke bed with a number of spoke holes, commonly produced by drilling. A tire bed may be radially outboard of the spoke bed and may lack holes aligned with the spoke holes. Lateral walls extend radially outward from opposite sides of the tire bed and cooperate with the tire bed to form a tire well. The rim may be substantially unitarily formed from a light alloy (e.g., aluminum alloy) or a fiber composite or other material. A clincher tire may be mounted in the tire well advantageously in the absence of a separate tube. A valve may be sealingly mounted in a valve hole in the tire bed and extending through a valve hole in the spoke bed for inflating the tire.

The present invention provides a spoke connection that may be blindly installed in the spoke bed. The connector may be economically produced using conventional manufacturing methods. The connection is easy to install and is serviceable in the field. The connection may be designed to provide a clean appearance with enhanced aesthetics. The connector may be made of high strength material(s), such as fiber-reinforced plastic or metals. The connector may have a large overlap with the spoke bed for increased robustness of the connection. The connector may be designed to minimize the size of the hole in the spoke bed, thereby increasing the strength of the bracing element (i.e. rim or hub). The connector may eliminate the necessity of a rim strip or rim tape. The resulting spoke connection is exceptionally robust and supports substantial spoke tension forces.

In contrast to prior art UK Patent Application GB2479870A by Jonathan Thulbon the connecting element of the present invention is comprised of two or more discreet segments. These segments are not required to flex during installation with the spoke bed and thus may be constructed of stronger and stiffer material (such as fiber reinforced polymer or metal) for increased robustness of the spoke connection. Further, since the segments are discreet, they may be installed in the spoke bed in sequential assembly steps, where each segment is installed in separate assembly steps. This permits the segment to include a comparatively larger lateral overhang surface and a correspondingly larger lateral depth of lateral overlap and engagement between the connecting element and spoke bed, thus reducing stresses at this interface and further strengthening the spoke connection. Still further, the overlie engagement between the spoke (or an intermediate connecting element connected to the spoke) and the connecting element may be located longitudinally outwardly from the outboard surface of the spoke bed, which does not require any longitudinally outward extension portions. This permits the corresponding hole in his spoke bed to be comparatively smaller. This smaller hole serves to further strengthen the spoke bed in this highly-loaded area. Yet further, the lack of such extension portions also serves minimize the tensile and bending stress on the connecting element due to spoke tension forces, further strengthening the spoke connection. Further still, the option of a longitudinal engagement permits a comparatively larger surface area of engagement than a single engagement location, which reduces stresses on the connector and spoke and allows for a minimized connector geometry, which requires a smaller hole in the spoke bed.

DETAILED DESCRIPTION OF THE INVENTION

FIG. 1describes the basic configuration of an exemplary prior art vehicle wheel, in particular, a bicycle wheel1, as well as a description of the direction conventions used throughout this disclosure. For clarity, the frame and the quick release skewer assembly are not shown in this figure. The hub shell14is rotatable about the axle9and includes at least two axially spaced hub flanges16, each of which include a means for connecting with the spokes2. Axle9includes end faces11aand11bthat define the spacing of its mounting with the frame (not shown). The axial axis28is the axial centerline of rotation of the bicycle wheel1. The hub flange16may be contiguous with the hub shell14or it may be separately formed and assembled to the hub body12portion of the hub shell14. The spokes2are affixed to the hub flange16at their first end4and extend to attach the rim8at their second end6. The tire10is fitted to the outer periphery of the rim8. The wheel ofFIG. 1is generic and may be of tension-spoke or compression-spoke design.

The axial direction92is any direction parallel with the axial axis28. The radial direction93is a direction generally perpendicular to the axial direction92and extending generally from the axial axis28radially outwardly toward the rim8. The tangential direction94is a direction generally tangent to the rim at a given radius. The circumferential direction95is a cylindrical vector that wraps around the axial axis28at a given radius. A radial plane96is a plane perpendicular to the axial axis28that extends in a generally radial direction at a given axial intercept. An axial plane97is a plane that is generally parallel to the axial axis. An axially inboard orientation is an orientation that is axially proximal to the axial midpoint between the two end faces11aand11b. Conversely, an axially outboard orientation is an orientation that is axially distal to the axial midpoint between the two end faces11aand11b. An axially inwardly facing surface is a surface that faces toward the axial midpoint between the two end fades11aand11b. Conversely, an axially outwardly facing surface is a surface that faces away from the axial midpoint between the two end faces11aand11b. Similarly, an axially inward direction is a direction that extends toward the axial midpoint between the two end faces11aand11b. Conversely, an axially outward direction is a direction that extends away from the axial midpoint between the two end faces11aand11b. A radially inboard orientation is an orientation that is radially proximal to the axial axis28and a radially outboard orientation is an orientation that is radially distal to the axial axis28.

While it is most common for the hub shell14to rotate about a fixed axle9, there are some cases where it is desirable to permit the axle9to be fixed with the wheel1, such as the case where the wheel1is driven by the axle9.

FIGS. 2a,2band2cdescribe the current technology in conventional bicycle wheels that most cyclists are familiar with. This prior art design includes a rim8, a hub shell14and a plurality of spokes2. The hub shell14is rotatable about the axle9and includes a pair of axially spaced hub flanges16. The wheel is assembled by first threading each individual spoke2through an axial hole17in the hub flange16until the j-bend19is hooked within the hole17. The spoke2is then pivoted to extend in a generally radial direction toward the rim8. The enlarged portion34or “head” of the spoke2prevents the spoke2from pulling through the hole17in the hub flange16. The second end6of each spoke2is then fixed to the rim8via spoke nipples21. Tightening the threaded engagement between the spoke nipple21and the spoke2serves to effectively shorten the length of the spoke2. Thus, as the nipples21are threadably tightened, the spokes are drawn up tight and a degree of pre-tension is induced in the spoke2. By selectively adjusting this threaded engagement, the spoke pre-tension may be adjusted to align the trueness of the rim8. The spoke pre-tension is resisted by circumferential compression of the rim8and it is this balance of forces that imparts efficient structural integrity to the bicycle wheel1. Also shown inFIG. 2bis bracing angle38between the radial centerline plane of the rim8and the tensile axis36of the spokes2. As this bracing angle38is increased, the lateral stiffness (i.e. stiffness in the axial direction92) of the wheel1is also increased.

FIG. 3ashows prior art single-wall rim18with a single lower web or spoke bed22wall. Rim18includes two hooked flanges26aand26bfor capturing the bead of a tire (not shown). Tire well24is a circumferential channel bounded by spoke bed22and flanges26aand26b. Spoke2includes threaded end31for threadable engagement with spoke nipple21. Rim18may be produced as an aluminum extrusion that also includes cavities29aand29bto accept pins (not shown) that serve to join the butted ends of the extruded profile to create a continuous rim hoop. During assembly, the threaded end31of spoke2is first positioned to extend through the inside diameter end of opening23. Next, the nipple21may be threadably assembled to the threaded end31of the spoke2through the outside diameter end of opening23. With all of the spokes2of the wheel assembled to the rim18in this way, a completed wheel assembly1is achieved. A rim strip (not shown) is commonly utilized to cover the radial outboard surface of the spoke bed and to protect the inner tube (not shown) from damage.

FIG. 3bshows a prior art rim20of double-wall configuration with an upper web or tire bed32wall and a lower web or spoke bed33wall. Rim10includes two hooked flanges36aand36bfor capturing the bead of a tire (not shown). Tire well24is a circumferential channel bounded by tire bed32and flanges36aand36b. Spoke bed33includes opening36and tire bed32includes concentric opening35, which serve to accept a spoke2and spoke nipple21. Spoke2includes threaded end31for threadable engagement with spoke nipple21. Rim18is produced as an aluminum extrusion that also includes an internal cavity20bounded by the spoke bed33, the tire bed32and sides25. It may be seen that, during assembly, the threaded end31of spoke2is first positioned to extend through the inside diameter end of opening35. Next, the nipple21is threadably assembled to the threaded end31of the spoke2first through opening35and then through opening36. With all of the spokes2of the wheel assembled to the rim in this manner, a completed wheel assembly is achieved. It may be seen that, with the nipple21bearing against the spoke bed32, opening35remains exposed as a passageway between the tire well24and the cavity20. A rim strip (not shown) is commonly utilized to cover the radial outboard surface of the spoke bed and to protect the inner tube (not shown) from damage.

FIG. 4shows an exemplary bicycle wheel644that corresponds to some of the embodiments described herein. This figure is shown to provide a generic assembly to illustrate an arrangement wherein the present invention may be adapted to utilization in bicycle wheel construction. The bicycle wheel644includes spokes100, rim648, hub assembly650and tire647. The hub assembly650includes hub shell651with flange portions655aand655b, axle652, axle caps653aand653band bearings654. The rim648includes tire bed649wall with geometry for mounting of a tire647and a spoke bed656wall with a multiplicity of spoke holes657, each to accept an individual connector578, and sidewalls658aand658bto define a cavity660. Hub shell651includes flange portions655aand655bwith a multiplicity of spoke holes662, each to accept an individual connector685.

It is noted that the rim648and hub shell451shown here are each exemplary representations of a bracing element that may take on a wide range of forms. The spokes100are connected at their first end663to flange portions655aor655band at their second end664to the rim648. Spokes100are connected to the rim648by means of sleeves86and connectors578as described in greater detail inFIGS. 5a-iand in other embodiments described herein. Spokes100are connected to the hub shell651by means of an overly connection between a spoke head portion534(not shown) and connectors685as described in greater detail inFIGS. 8a-cand other embodiments described herein. While the term “spoke bed” is commonly used in reference to the outer rim, as described herein, the term “spoke bed” may also refer to the portion of the hub shell to which the spoke is connected (i.e. flange portions655aand655b).

The spoke100is a generally long slender tensile element with a longitudinal axis37along its length and generally parallel to its sidewalls. The spoke100also has a terisile axis36of applied tensile load, which is generally collinear to the longitudinal axis. For the purposes of definition, the term “longitudinal” herein refers to alignment generally coincident or parallel to the longitudinal axis37. Further, the term “lateral”, as defined herein, refers to alignment and/or orientation in a direction that is generally orthogonal to the longitudinal axis37.

The connectors578and685are generally shown to serve as terminations to the spoke100and provide means to connect or anchor the spoke100to a bracing element (i.e. rim648and/or hub shell651). Note that the span of spoke100is aligned in the direction of spoke tension30and along the tensile axis36, which extends through the longitudinal axis37of the spoke100. It is shown here that several spokes100of the wheel644may be terminated in this manner. For simplicity in describing many of these embodiments, a rim connection arrangement may be described, with the understanding that such an embodiment may be easily adapted to hub connections as well. It is understood thatFIG. 4corresponds to a simplified arrangement for illustration purposes. Several of the embodiments of the present invention may be applied to this arrangement, as well as arrangements which include facility for creating and/or adjusting spoke pre-tension, as described inFIGS. 5a-i.

The present invention comprises a spoke (i.e. spoke100), which may be considered as a longitudinal tensile element having an end portion and a cross-section thereof, a connecting element (i.e. connectors578and685), a bracing element (i.e. hub shell651and rim648), and a tensile axis of applied tensile load along the longitudinal tensile element. The spoke is connected to the connecting element by means of an overlie engagement and/or a longitudinal engagement between the spoke (and/or an intermediate element connected to the spoke) and the connecting element. In the embodiments shown herein, the longitudinal tensile element is a vehicle wheel spoke, the hub shell or hub flange constitutes a first bracing element and the outer rim constitutes a second bracing element.

A longitudinal tensile element (i.e. spoke) is a generally long slender element, with a length greater than its cross sectional width, and with a longitudinal axis37extending generally along its length. The spoke includes external sidewall surface(s) that extend generally along its length. As such, the longitudinal axis37is generally parallel to the sidewall surface. The tensile axis36is the axis along which tensile loads (i.e. spoke tension30) are applied to the tensile element, and is commonly collinear with the longitudinal axis37, particularly in the region of the structural span of the spoke. For the purposes of explanation herein, the term “longitudinal axis” is generally interchangeable with the term “tensile axis” unless otherwise noted. Some examples of a longitudinal tensile element include the spoke of a vehicle wheel, a guy wire, a control cable, or a tendon. In most of the embodiments of the present invention, the longitudinal tensile element is capable of supporting load in tension, otherwise known as positive tensile loading, along its length. However, the longitudinal tensile element may alternatively support load in compression along its length, otherwise known as negative tensile loading, where the longitudinal tensile element provides columnar support between two bracing elements. The spoke span is considered as the portion of the spoke that is under tension (or compression) and that extends between its anchor points and/or engagements at the bracing elements (i.e. hub and rim). A location outboard of the spoke span is a location along the tensile axis36that is beyond or external to the spoke span. Further, a longitudinally outward orientation refers to an orientation along the longitudinal axis that is distal from the midpoint of the span. Conversely, a longitudinally inward orientation refers to an orientation along the longitudinal axis that is proximal to the midpoint of the span.

For the purposes of using conventional terminology, the term “hub flange” is used herein to describe a region of the hub shell to which the spokes are joined. While the surface of the hub flange may be raised and flange-like in comparison to other surfaces of the hub shell14, this is not a requirement for the present invention and the hub flange may alternatively be flush or recessed relative to other hub shell surfaces. An overlie engagement between two elements is an engagement wherein a first element includes a laterally extending surface that extends generally laterally from the direction of load. This laterally extending surface overlaps or overlies a mating surface or edge of the second element such that the first element is engaged and connected to the second element in the direction of load. The overlie engagement is preferably capable of supporting this load and maintaining this connection.

It may be termed that a longitudinal engagement is an engagement that includes a continuous longitudinal engagement interface or an engagement that includes at least two engagement interface locations that are longitudinally spaced along the longitudinal axis of the spoke. It is generally desirable that the longitudinal length of such an engagement be greater than the cross-sectional thickness of the spoke to create an effective engagement. Obviously, increasing the length of engagement may serve to increase the interface surface area and may therefore increase the load carrying capacity of a corresponding joinder between the connector and the spoke. A threaded engagement, with its continuous helix of engagement along a longitudinal length, is considered to be a longitudinal engagement.

A bracing element is one that resists or braces against all or part of the load of a tensile element. In other words, in order for a tensile element (i.e. spoke) to maintain its tension (or compression) and remain a generally static structure, it must have a resisting or bracing element to bear against. Thus, the tensile element is generally anchored to two bracing elements and the tensile element thereby serves to connect the two bracing elements to each other. In an example where the tensile element is generally held in tension, such as the spoke of a tension-spoke vehicle wheel, a first bracing element could be the hub flange and a second bracing element could be the outer rim hoop. Similarly, in the case where the tensile element is generally held in compression, such as the spoke of a compression-spoke vehicle wheel, the bracing element is that element which the tensile element is pushed against.

The term “blind connection” or “blind engagement” is well known in industry and refers to a connection between a first and second element where the first element may be connected to the second element without necessarily requiring access to both sides of the second element. For example, in a blind connection, a spoke may be connected to a hole in a rim by manipulating the spoke (or a connector associated with the spoke) through the first end of the hole without requiring access to the opposite end of this hole. Such a blind connection is particularly useful when access to the opposite end of the hole is limited or restricted or when the opposite end of the hole is otherwise obscured. As an example relating to several of the embodiments of the present invention, a blind connection between the spoke and the spoke bed is shown to be achieved by means of access only to the opening of the hole at the inboard surface of the spoke bed and without requiring access to the outboard surface of the spoke bed. As such, the blind connection provided by the present invention is particularly advantageous since the connection between the spoke and the spoke bed may be achieved by means of assembly and manipulation only through the accessible exterior of the bracing element and does not require access to the inaccessible interior of the bracing element. Such a blind connection has particular utility in double-wall rims for tubeless tires where the tire bed wall may advantageously remain unpierced to provide effective sealing of the internal cavity of the tire. This unpierced tire bed wall serves to obscure the longitudinally outward end of the hole in the spoke bed.

FIGS. 5a-idescribe an embodiment illustrating a blind connection between the spoke and the spoke bed, showing the spoke bed568, connector578, sleeve86and spoke100. As shown inFIGS. 5aand5f, spoke bed568includes a radially outboard surface571, a radially inboard surface572. Spoke bed568also includes a hole573therethrough with hole sidewall574and circular diameter575. Hole573extends along central axis569, which is shown here to be generally perpendicular to the outboard surface571. Spoke bed568is shown in fragmentary view for illustration purposes and it is understood that spoke bed568constitutes a portion of the rim or hub flange to which the connector578is attached. The outboard surface571represents a longitudinally outward surface adjacent the longitudinally outward opening of hole573. Similarly, the inboard surface568represents a longitudinally inward surface adjacent the longitudinally inward entrance or opening of hole573. While these surfaces are shown to be generally flat, planar, and orthogonal to the central axis569, this is merely a representative arrangement and these surfaces may incorporate a wide range of geometries, including curved geometry, stepped geometry, projecting surfaces, recessed surfaces, conical, spherical, etc.

Spoke100includes a shank portion101extending along longitudinal axis37, an enlarged head102and a laterally projecting transition surface104therebetween. Sleeve86includes external threads88, a longitudinal hole90therethrough, and countersink91matched to nest with transition surface104. Sleeve86also includes flats89to create a noncircular portion that may be manually manipulated with a wrench (not shown). The spoke100is shown inFIGS. 5aand5fto be loosely preassembled to the sleeve86, with the shank portion101extending through the hole90along the longitudinal axis37.

As particularly illustrated inFIG. 5b, connector578is a multi-piece connector consisting of individual segments580aand580b, each include associated flange portions588aand588bwith flats589, collar portions582aand582b, enlarged portions584aand584b, ramped surfaces587aand587band overhang surfaces586aand586brespectively. Segments580aand580balso include semi-circular cylindrical reliefs590aand590brespectively, with corresponding internal thread portions592aand592bthat extend along opening axis591. As particularly shown inFIG. 5h, collar portions582aand582bhave a width593across their external surfaces and enlarged portions584aand584bhave a width594across their outer surfaces, with overhang surfaces586aand586bhaving widths595aand595brespectively. Cylindrical reliefs590aand590bextend longitudinally along the opening axis591through their flange portions588aand588b, collar portions582aand582b, and enlarged portions584aand584brespectively. Connector578is shown in greater detail inFIG. 5b. Segment580ais shown to be in a generally laterally opposed orientation relative to segment580b, with reliefs590aand590bfacing each other. It is envisioned that the connector578may be made of a wide range of materials, including a polymeric resin, fiber-reinforced polymeric resin, aluminum, magnesium, zinc or a variety of other materials. In a preferred arrangement, the segments580aand580bmay be made of fiber reinforced polymer, with the sleeve made of aluminum and the spoke made of stainless steel. The design of segments580aand580bis such that they may be easily formed in a variety of conventional manufacturing processes, including molding, casting, forging, etc.

FIGS. 5cand5gshow a first assembly step in connecting the spoke100to the spoke bed568. Segment580ais first shown to be pre-assembled to the hole573, first in direction599a, which is a generally longitudinal direction, until overhang586ais aligned with outboard surface571, then in direction598auntil collar portion582ais contacting and nested within sidewall574and longitudinally overlapping the sidewall574. Direction598ais a generally lateral direction relative to direction599aand serves to laterally shift and spread segment508ain a distal orientation relative to the central axis569. Flange portion588ais now abutting inboard surface572and overhang surface586ais overlying, hooking and engaged to outboard surface571. It is noted that, as segment580ais inserted through hole573, with enlarged portion584aaligned with hole sidewall574, segment580ais in a laterally contracted orientation that is proximal to segment580b. Then, when segment580ais shifted in direction598a, it achieves a laterally expanded orientation that is laterally distal to segment580b. It is noted that the sidewall574serves to provide a limit stop to control the lateral displacement of the collar portions582aand582in directions598aand598brespectively.

FIGS. 5dand5hshow a second assembly step in connecting the spoke100to the spoke bed568. Segment580bis next shown to be inserted within the hole573, first in direction599b, which is a generally longitudinal direction, until overhang surface586bis aligned with outboard surface571, then laterally shifted in direction598buntil collar portion582bis contacting and nested within sidewall574and longitudinally overlapping the sidewall574. Direction598bis a generally lateral direction relative to direction599band serves to laterally shift and spread segment508bin a distal orientation relative segment508aand to the central axis569. Flange portion588bis now abutting inboard surface572and overhang surface586bis overlying, hooking and engaged to outboard surface571. It is noted that, as segment580bis inserted through hole573, with enlarged portion584baligned with hole sidewall574, segment580bis in a laterally contracted or collapsed orientation that is proximal to segment580a. Then, when segment580bis shifted in direction598b, it achieves a laterally expanded orientation that is laterally distal to segment580a. Segments580aand580bare now preassembled to the spoke bed568.

With segments580aand580bopposed and fully seated in respective directions598aand598bas shown, gaps597aand597bare created at the seam between the two segments. These gaps597aand597bare necessary to provide the requisite clearance to allow segment580bto collapse against segment580aand to permit enlarged portion584bto clear the hole573during the second assembly step. Thus, the connector578may achieve an unexpanded or collapsed orientation such that width594is reduced to allow the enlarged portions584aand/or584bto pass through the hole573as described in these figures. Further, the connector578may achieve an open, spread or expanded orientation such that width594is expanded to the extent that collar portions582aand582bare fully nested and seated against sidewall574and overhang surfaces586aand586boverlie the outboard surface571as shown.FIGS. 5dand5hshow the segments580aand580bas expanded and spread apart in directions598aand598brespectively.

It is preferable that the overhang surfaces586aand586bbe generally matched to the outboard surface571in a surface-to-surface overlie engagement. This maximizes the area of contact and minimizes the contact stress at this engagement interface. Alternatively, the overhang surfaces586aand586bmay contact only an edge of the spoke bed568, such as the longitudinally outward edge of the hole573, in a surface-to-edge overlie engagement. Such an engagement has comparatively reduced contact area and results in higher contact stress.

As described inFIGS. 5a-i, segment580ais installed and inserted in the hole573in a first assembly step and segment580bis installed and inserted in the hole573in a second assembly step. This multi-step sequence may be considered “sequential” installation of the segments. Since segment580ais installed alone in the first assembly step, it may permit a relatively large width595aof overhang surface586ato the extent that it may still fit and permit installation within the hole573. As shown inFIG. 5h, the width595aof overhang surface586ais larger than the width595bof overhang surface586b. Since the width595ais maximized for sequential installation, when the enlarged portion584ais advanced in direction599asuch that enlarged portion584ais aligned with sidewall574, then the hole573may be blocked to a degree that segment580bmay be temporarily restricted from simultaneously advancing through hole573.

The lateral shift of segment580ain direction598a, as shown inFIG. 5gcorresponds to this larger width595a. With the segment580aalready in place, only a narrower portion of the hole573remains available for installation of segment580bas shown inFIGS. 5cand5gand as described in the second assembly step. Thus, the available width595bof overhang surface586bis often more limited and reduced relative to the larger width595a. To maximize width595b, segment580bis preferably pressed against segment580aduring its installation and fitment within hole573in direction599bas described. When segment580bis then shifted in direction598b, gaps597aand597bare created (as shown inFIGS. 5dand5h), whose width600generally corresponds to the width595bof overhang surface586b. It may likely be preferable to minimize the width600of gaps597aand597bwhile maximizing the width595bto increase the robustness of the overlie engagement and connection between the connector578and the spoke bed586.

One of the advantages of the present invention is that its discreet segments (580aand580b) may accommodate such sequential installation. However, as an alternative, both segments580aand580bmay be installed through hole573at the same time. Such a single-step assembly sequence may be considered “simultaneous” installation. In such a case, both segments580aand580bmust be fitted within hole573at the same time, necessitating that widths595aand595bbe reduced. Thus, in such simultaneous installation, even if segments580aand580bare fully collapsed and pressed against each other during installation, the width600of gaps597aand597bgenerally corresponds to the combined widths595aand595bof overhang surfaces586aand586b. In sequential installation, both enlarged portions584aand584bmust clear the sidewall574simultaneously during installation. Thus, in contrast to sequential installation, simultaneous installation results in more challenging geometry restrictions that reduce the clearance and space available to accommodate widths595aand595band also may require increased width600of gaps597aand597b. Since it is often preferable to maximize widths595aand595band to minimize width600to maximize the robustness of the connection between the connector578and the spoke bed568, it may be seen that sequential installation may be preferable to simultaneous installation.

Further, with segments580aand580bfully seated in hole573as shown inFIGS. 5dand5h, cylindrical reliefs590aand590bcombine to create a generally circular cylindrical opening596that extends in a generally longitudinal direction along opening axis591. It is noted that the central opening596and gaps597aand597ball constitute portions of a general opening between segments580aand580b. Internal thread portions592aand592bare now matched and combined to create a continuous helical internal thread profile that may threadably engage with the external threads88of the sleeve86. Also, it may be seen that the flange portions588aand588bcombine to create a generally hexagonal and noncircular profile that includes flats589such that it may be manually manipulated with a wrench (not shown).

Flange portions588aand588bpreferably include laterally projecting geometry that is sized to extend outside the perimeter of hole573and to laterally overlie the inboard surface572adjacent the hole573. Thus, by contacting and abutting the inboard surface572, the flange portions588aand588bmay serve to provide a depth stop to their respective segments580aand580b, limiting their advancement in respective directions599aand599bduring assembly to insure proper alignment between overhang surfaces586aand586band outboard surface571. Further, the overlie of the flange portions588aand588bmay serve to retain the segments580aand580bto the hole573, thus preventing them from inadvertently advancing too far beyond the outboard surface571and potentially becoming lost and disengaged with the spoke bed568. While flange portions610aand610bprovide the convenience of a depth stop and provide the convenience for manual manipulation as described, it is understood that these functions may not be critical for proper function of the corresponding segments580aand580band that flange portions588aand588bmay alternatively be omitted and/or may have an alternate geometry form.

FIGS. 5eand5ishow a third assembly step in connecting the spoke100to the spoke bed568. The sleeve86is threadably engaged with the opening596created between segments580aand580b, with external threads88threadably engaged with internal thread portions592aand592b. It is shown here that opening axis591is generally parallel and coaxial with central axis569. Alternatively, opening axis591may be offset parallel or at an angle relative to central axis569.

The opening596of the connector578is now essentially plugged and filled by the sleeve86, thus providing a bracing and blocking engagement between the cylindrical reliefs590aand590bto limit the laterally proximal or inward movement of the segments580aand580band thus preventing the connector578from inadvertently achieving an unexpanded or collapsed orientation. The segments580aand580bare now locked in their expanded or open and spread orientation relative to each other. Thus, the overlie engagement between the overhang surfaces586aand586band the outboard surface571is now maintained by the sleeve86, thereby locking and engaging the connector578to the spoke bed568. Further, the sleeve86is now threadably engaged to the connector578in a longitudinal engagement that occurs over at least a portion of the longitudinal length of the opening596. This longitudinal engagement is particularly advantageous for several reasons: Firstly, since the engagement extends along the collar portions582aand582b, enlarged portions584aand584b, and flange portions588aand588b, this threaded engagement serves to longitudinally engage segments580aand580bto each other; Secondly, the lateral width of the engagement is minimized since cumulative lateral engagement width of the full thread helix results in a significant projected area of overlie engagement that is equivalent to the area of a much larger lateral overlie width in a single overlie engagement.

Finally, as spoke tension30is applied to the spoke100along tensile axis36, the spoke100is drawn longitudinally inwardly and the transition surface104, which may be considered to be a laterally projecting surface, is nested within the countersink91in an overlie engagement. Thus the spoke100is connected and engaged with the sleeve86, which is connected and engaged to the connector578, which is connected and engaged to the spoke bed568. It should be noted that the sleeve86serves as an intermediate connecting element between the spoke100and the connector578. These connections and engagements effectively join the spoke100to the spoke bed568to resist spoke tension30. Thus, a blind connection between the spoke100and the spoke bed568is achieved. This blind connection is achieved through manipulation of the spoke100, connector578and sleeve86only on the inboard surface572side of the spoke bed568, without requiring access to the outboard surface571side of the spoke bed568. It may be seen that the present invention provides particular advantage in the spoke bed of a tubeless tire rim application, since the sealed tire bed (not shown) is not required to be pierced and may now be used as a sealing air barrier.

Since a portion of internal thread portions592aand592bextend longitudinally through the corresponding enlarged portions584aand584b, a portion of their threaded engagement with external threads88is shown to be longitudinally outward of the overhang surfaces586aand586b. Thus, the a portion of the overlie engagement between the collar86and the connector578is longitudinally outward of the outboard surface571as well. This is preferable, since it serves to provide increased support and reduced stress in the connector578.

The spoke tension30pre-load may be adjusted as previously described by threadably adjusting the external threads88relative to the internal thread portions592aand592bby means of a wrench (not shown) engaged to flats89. This rotation of the sleeve86may be independent of the rotation of the spoke100about the longitudinal axis37, with the sleeve86rotating relative to spoke100. Alternatively, the spoke100may be rotationally fixed to the sleeve86, such that the spoke rotates with the sleeve86about the longitudinal axis37. Further, the connector66may be prevented from inadvertently rotating during this adjustment by means of a wrench (not shown) engaged with flats589. Alternatively, the sleeve86may be held fixed, while the connector578is rotated relative to the sleeve86about the opening axis591.

The spoke100and connector578may be disassembled in the reverse of the three assembly steps just described. First, the sleeve86is unscrewed from the connector578. Second, the segment580bis collapsed against segment580ain direction598a, reducing or eliminating gaps597aand597b. Overhang surface586bis no longer overlying outboard surface571and segment580bmay be withdrawn from hole573in a longitudinally inward direction opposite direction599b. Third, segment580ais laterally shifted in direction598bsuch that overhang surface586ais no longer overlying outboard surface571. Segment580amay now be withdrawn from hole573in a direction opposite direction599a.

Since light weight and low cost of the connector578are desirable attributes, it is preferable that the segments580aand580bbe formed from a polymeric material, such as an engineering thermoplastic, or from a light metal, such as aluminum. However a wide range of other materials may be utilized to produce the connector578.

While opening596, comprised of cylindrical reliefs590aand590b, include internal thread portions592aand592bthat extend the full longitudinal length of the connector578, it is also envisioned that cylindrical reliefs590aand/or590bmay alternatively include thread portions that extend along only a portion of the longitudinal length. Further, while cylindrical reliefs590aand590bare shown to include pre-formed internal thread portions592aand592b, it is also envisioned that the cylindrical reliefs590aand590bmay alternatively be smooth. In this case, as the sleeve86is forcibly threaded into the opening596, the external threads88may form internal threads in the formerly smooth cylindrical reliefs590aand590bin a self-tapping arrangement well known in industry. Further still, if cylindrical reliefs590aand590bwere alternatively formed to be smooth and unthreaded, internal thread portions592aand592bmay be formed in a conventional tapping operation subsequent to the installation of segments580aand580b. Still further, while connector578is shown to be composed of two discreet and opposed segments580aand580b, it is also envisioned that the connector may alternatively be composed of three or more discreet segments.

FIGS. 6a-jdescribe an embodiment illustrating a blind connection between the spoke394and the spoke bed568, showing the connector606, spoke bed568, nipple386and spoke394. Nipple386is of generally conventional configuration and includes a shank portion388, an enlarged head portion393of diameter398, and a transition surface392therebetween, and flats389such that it may be manually manipulated with a wrench (not shown). Transition surface392is shown here to be a generally planar and laterally projecting surface, extending perpendicular to the longitudinal axis37. Nipple386also includes longitudinal hole390therethrough with internal threads391to threadably mate with external threads395of spoke394. Spoke394includes an end portion396with external threads395. The spoke394is shown inFIG. 5ato be threadably preassembled to the nipple386, with external threads395mated to internal threads391and with the end portion396extending through the hole390along the longitudinal axis37.

Spoke bed568is identical to that shown inFIGS. 5a-iand is shown in fragmentary view for illustration purposes. Spoke bed568constitutes a portion of the rim or hub flange to which the connector606is attached. Connector606is a multi-piece connector consisting of segments608aand6080b, each include associated flange portions610aand610bwith flats611, collar portions612aand612b, enlarged portions614aand614b, end faces617aand617b, and overhang surfaces616aand616brespectively. Segments608aand608balso include semi-circular cylindrical reliefs618aand618brespectively. Cylindrical reliefs618aand618bextend longitudinally along the opening axis622through their flange portions610aand610b, collar portions612aand612b, and enlarged portions614aand614brespectively. Connector606is shown in greater detail inFIG. 6b.

FIGS. 6cand6gshow a first assembly step in connecting the spoke394to the spoke bed568. Segment608ais first shown to be pre-assembled to the hole573, first in direction626until overhang surface616ais aligned with outboard surface571, then in direction625auntil collar portion612ais nested within sidewall574. Flange portion610ais now abutting inboard surface572and overhang surface616ais overlying, hooking and engaged to outboard surface571. It is noted that, as segment608ais inserted through hole573, with enlarged portion614alongitudinally overlapping with hole sidewall574, segment608ais in a laterally contracted orientation that is proximal to segment608b. Then, when segment608ais shifted in direction625a, it achieves a laterally expanded orientation that is laterally distal to segment606b.

FIG. 6hshows the initiation of a second assembly step where the segment608bis laterally collapsed and contracted in direction625atoward the previously installed segment608ato permit enlarged portion614ato clear the hole573as the segment is advanced in direction626during this assembly step. Enlarged portion614bis shown to be longitudinally overlapping hole sidewall574along the central axis569.

FIGS. 6dand6ishow a completed second assembly step in connecting the spoke394to the spoke bed568. Segment608bis now shown to be pre-assembled to the hole573, first in direction626until overhang surface616bis aligned with outboard surface571, then in direction625buntil collar portion612bis nested within sidewall574. Segment608bnow has a laterally expanded orientation that is laterally distal to opposing segment608a. Flange portion610bis now abutting inboard surface572and overhang surface616bis overlying, hooking and engaged to outboard surface571. With segments608aand608bopposed and fully seated as shown, the connector606is considered to be open, spread or laterally expanded, such that gaps627are created between the two. These gaps627are necessary to provide the requisite clearance to allow segment608bto collapse against segment608aand to permit enlarged portion614bto clear the hole573during the second assembly step. Thus, the connector606may achieve an unexpanded or collapsed orientation such that width629is reduced to allow the enlarged portions614aand614bto pass through the hole573as shown. Further, the connector578may achieve an open, spread or expanded orientation such that width629is expanded to the extent that collar portions608aand608bare fully nested and seated against sidewall574and overhang surfaces616aand616boverlie the outboard surface571as shown.

Further, with segments608aand608bfully seated as shown, cylindrical reliefs618aand618bcombine to create a generally circular cylindrical opening620, with opening axis622. In contrast to the embodiment ofFIGS. 5a-i, where opening596includes internal thread portions592aand592b, opening620is shown to be smooth and cylindrical. Also, it may be seen that the flange portions610aand610bcombine to create a generally square and noncircular profile that includes flats611such that it may be manually manipulated with a wrench (not shown). It is shown here that opening axis622is generally parallel and coaxial with central axis568. Alternatively, opening axis622may be offset and parallel or at an angle relative to central axis568.

Flange portions610aand610bpreferably include geometry that is sized to extend laterally outwardly beyond the perimeter of hole573and to overlie the inboard surface572adjacent the hole573. Thus, by contacting the inboard surface572, the flange portions610aand610bmay serve to provide a depth stop to their respective segments608aand608b, limiting their advancement in direction626during assembly to insure proper alignment between overhang surfaces616aand616band outboard surface571. Further, the overlie of the flange portions610aand610bmay serve to retain the segments608aand608bto the hole573, thus preventing them from inadvertently advancing too far beyond the outboard surface571and potentially becoming lost and disengaged with the spoke bed568. While flange portions610aand610bprovide the convenience of a depth stop and provide the convenience for manual manipulation as described, it is understood that these functions may not be critical for proper function of the corresponding segments608aand608band that flange portions610aand610bmay be omitted and/or may have an alternate geometry form.

Next, as shown inFIGS. 6eand6j, spoke394and nipple386are together drawn in direction630along the opening axis622such that shank portion388extends through opening620and transition surface392contacts and abuts end faces617aand617b. The diameter of shank portion388is a close fit with opening620while the connector606is in its expanded, spread, or open orientation, with shank portion388extending through and contacting both cylindrical reliefs618aand618b, thus providing a bracing and blocking engagement between the segments608aand608bto limit the laterally proximal or inward movement of the segments608aand608band preventing the connector366from inadvertently achieving an unexpanded or collapsed orientation. The segments608aand608bare now locked in their expanded or open and spread orientation. Thus, the overlie engagement between the overhang surfaces616aand616band outboard surface571is now maintained, thereby locking the connector606to the spoke bed568.

Further, the laterally projecting transition surface392now has an overlie blocking engagement with end faces617aand617b. The nipple386is thus engaged to the connector606to resist spoke tension30forces along tensile axis36and to retain the spoke394to the spoke bed568. Thus the spoke394is connected and engaged with the nipple386, which is connected and engaged to the connector606, which is connected and engaged to the spoke bed568. It should be noted that the nipple386serves as an intermediate connecting element between the spoke394and the connector606. These connections effectively join the spoke394to the spoke bed356to resist spoke tension30. Thus, a blind connection between the spoke394and the spoke bed356is achieved. It may be seen that the present invention, when use to provide a blind spoke connection to the rim, provides particular advantage in tubeless tire configurations, since the sealed tire bed (not shown) is not required to be pierced and may now be used as a sealing air barrier. Spoke tension may be adjusted in the conventional manner, with nipple386rotated independently of the spoke394about the longitudinal axis37to threadably adjust the engagement between internal threads391and external threads395. Further, nipple386may be rotated independently of the connector606about the opening axis622. Alternatively, the nipple386may be rotatably fixed relative to the connector606and/or the spoke394.

It is noted that end faces617aand617bconstitute the longitudinally outward terminus of the connector606and that the overlie engagement between transition surface392and end faces617aand617bis located to be longitudinally outward from the outboard surface571. This is preferable, since it allows the diameter575of hole573to be sized for close clearance fit with the diameter398of head portion393. This permits the diameter575of the hole573to be minimized to insure the minimum amount of material removal (due to hole573) and the maximum strength of the spoke bed568. Alternatively, the overlie engagement between transition surface392and end faces617aand617bmay be located longitudinally inward from the outboard surface571. However, this requires that the segments608aand608bmust also include extension geometry that surrounds the head portion393and extends longitudinally outwardly through the hole573such that overhang surfaces616aand616bmay engage the outboard surface571. Thus, the diameter575of hole573must now be substantially larger than the diameter398of the head portion393, since it must also accommodate this additional extension geometry of the segments. The larger hole573is less preferable, since it corresponds to more material removal and greater weakness of the spoke bed568. The spoke bed568may require greater thickness and weight as a result.

Since the shank portion388extends through the opening620, flats611are now accessible on the exposed longitudinally inward side of spoke bed568, the nipple386may be threadably adjusted relative to the spoke394and the spoke tension30pre-load may be adjusted as previously described by means of a wrench (not shown) engaged to flats389. Further, the connector606may be prevented from inadvertently rotating during this adjustment by means of a wrench (not shown) engaged with flats611.

The embodiment ofFIGS. 7a-cis similar to the embodiment ofFIGS. 6a-j. However, whileFIGS. 6a-jshows a nipple386with a circular cylindrical shank portion388,FIGS. 6a-dshows a nipple670with a non-circular shank portion672that includes longitudinal ribs674aand674b. Spoke bed568is identical to that shown and described inFIGS. 5a-iand is shown in fragmentary view for illustration purposes. It is understood that spoke bed568constitutes a portion of the rim or hub flange to which the connector606is attached. The connector606is identical to that shown and described inFIGS. 6a-jand includes segments608aand608b.

Nipple670includes a shank portion672with longitudinal ribs674aand674b, an enlarged head portion682and a transition surface680therebetween. Transition surface680is shown here to be generally planar and perpendicular to the longitudinal axis37. Nipple670also includes a countersink679and longitudinal hole678therethrough to accept the spoke100. Spoke100is identical to that described inFIG. 5a-i. The spoke100is shown inFIG. 7ato be loosely preassembled to the nipple670, with the shank portion101extending through the hole678along the longitudinal axis37.

As shown inFIG. 7a, nipple670and spoke100are first inserted through hole573in direction681, with nipple670longitudinally outward of outboard surface571and with spoke100extending through the hole573. Segments608aand608bare positioned to be assembled to spoke bed568as previously described inFIGS. 6a-j.

As shown inFIGS. 7band7c, the segments608aand608bare shown to be assembled to the spoke bed568in general direction681in a manner identical to that described inFIGS. 6a-j. The overhang surfaces616aand616bnow overlie the outboard surface571and retain the connector606within the hole573. Gaps627are shown between segments608aand608b, as also described inFIGS. 6a-j. Spoke100and nipple670are also shown to both be drawn in direction677along the opening axis622such that shank portion672extends through opening620and the laterally projecting transition surface680contacts end faces617aand617b. It is noted that ribs674aand674bare also aligned to be longitudinally overlapping and nested within their corresponding gaps627.

The diameter of shank portion672is a close fit with opening620while the connector606is in its expanded or open orientation, with shank portion672bracing across both cylindrical reliefs618aand618b, thus providing a bracing and blocking engagement between the segments608aand608bto limit the laterally proximal or inward movement of the segments608aand608band preventing the connector606from inadvertently achieving an unexpanded or collapsed orientation. The segments608aand608bare now locked in their expanded or open and spread orientation. Thus, the overlie engagement between the overhang surfaces616aand616band outboard surface571is now maintained, thereby locking the connector606to the spoke bed568.

Further, the ribs674aand674bare nested and longitudinally overlapping gaps627. Additionally or alternatively to the bracing function of the shank portion672described above, ribs674aand674bmay serve to brace across gaps627, thus providing a bracing and blocking engagement between the segments608aand608bto limit the laterally proximal or inward movement of the segments608aand608band preventing the connector606from inadvertently achieving an unexpanded or collapsed orientation. In addition, the engagement between ribs674aand674band gaps627serve to rotationally key and lock the nipple670and connector606to each other about the opening axis622. The segments608aand608bare now locked in their expanded or open and spread orientation. Thus, the overlie engagement between the overhang surfaces616aand616band outboard surface571is now maintained, thereby locking the connector606to the spoke bed568. Finally, as spoke tension30is applied to the spoke100along tensile axis36, the spoke100is further drawn in direction677and the laterally projecting transition surface104is nested within the countersink679in an overlie engagement.

Further, transition surface680now has an overlie blocking engagement with end faces617aand617band the nipple670is now engaged to the connector606to resist spoke tension30forces and to retain the spoke100to the spoke bed568. Transition surface104is now nested within countersink679to create an overlie engagement between spoke100and nipple670. Thus the spoke100is connected and engaged with the nipple670, which is connected and engaged to the connector606, which is connected and engaged to the spoke bed568. It should be noted that the nipple670serves as an intermediate connecting element between the spoke100and the connector606. These connections effectively join the spoke100to the spoke bed568to resist spoke tension30along tensile axis36. Thus, a blind connection between the spoke100and the spoke bed568is achieved.

The embodiment ofFIGS. 8a-cis similar to the embodiment ofFIGS. 6a-j. However, whileFIGS. 6a-jshows a nipple386as an intermediate connecting element and shows a connector606with a straight opening620,FIGS. 8a-celiminates the nipple386in favor of a cylindrical head portion534that is integral with the spoke530and utilizes a connector685with a stepped opening692. Spoke bed568is identical to that shown and described inFIGS. 5a-iand is shown in fragmentary view for illustration purposes. It is understood that spoke bed568constitutes a portion of the rim or hub flange to which the connector685is attached. The spoke530includes shank portion532and an enlarged head portion534of diameter535, with a transition surface536on the underside of the head portion534and extending to the shank portion532. Transition surface536is shown here to be generally planar and perpendicular to the longitudinal axis37.

Connector685is shown in greater detail inFIG. 8band is composed of two segments686aand686b, each including associated flange portions690aand690b, collar portions687aand687b, enlarged portions688aand688b, end faces683aand683b, and overhang surfaces689aand689brespectively. The opening692is created by cylindrical reliefs691aand691band extends along the opening axis693as shown. In contrast to opening620ofFIGS. 6a-g, the opening692is stepped to include respective enlarged counterbore portions695aand695b, smaller necked openings697aand697b, and lateral step face portions696aand696bextending therebetween respectively. Step face portions696aand696bare shown here to be generally planar and perpendicular to the longitudinal axis37upon final assembly. With segments686aand686bopposed and fully seated as shown inFIG. 8c, gaps694are created between the two, as previously described inFIGS. 5a-iandFIGS. 6a-j. The collar portions687aand687bare laterally offset from their respective counterbore by offset distances703aand703b.

The spoke530is shown inFIG. 8ato first be preassembled to the spoke bed568in direction698with head portion534extending longitudinally outward of outboard surface571and with shank portion532extending through hole573. The segments686aand686bare positioned longitudinally inward of inboard surface572, with the shank portion532also extending between segments686aand686b. Next, the connector685is assembled to the spoke bed568, in a manner as described inFIGS. 6a-j, such that overhang surfaces689aand689bengage outboard surface571as shown inFIG. 9c.

Next, as also shown inFIG. 8c, spoke530is drawn in direction699along the opening axis693such that shank portion532extends through necked openings697aand697b, head portion534is nested in counterbore portions695aand695band laterally projecting transition surface536abuts and overlies step faces696aand696b. The diameter of head portion534is a close fit with counterbore portions695aand695b, thus providing a bracing and blocking engagement between the counterbore portions695aand695bto limit the laterally proximal or inward movement of the segments686aand686band prevent the connector685from inadvertently achieving an unexpanded or collapsed orientation. The segments686aand686bare now locked in their expanded or open and spread orientation. Thus, the overlie engagement between the overhang surfaces689aand689band outboard surface571is now maintained, thereby locking the connector685to the spoke bed568.

Finally, as spoke tension30is applied to the spoke484, the spoke484is pulled in direction699and the transition surface489bears against step faces696aand696bin an overlie engagement. The spoke530is now directly engaged to the connector685to resist spoke tension30forces along tensile axis36and to retain the spoke530to the spoke bed568. Thus, a blind connection between the spoke530and the spoke bed568is achieved. It is noted that the spoke530is shown in this embodiment to be directly connected and engaged to the connector685. This is in contrast to the embodiments ofFIGS. 5a-i,FIGS. 6a-j, andFIGS. 7a-cwhere an intermediate connecting element is utilized (i.e. sleeve86, nipple386, nipple670) for linked connection where the spoke is connected to the intermediate connecting element and the intermediate connecting element is connected to the connector.

It is noted that the overlie engagement between transition surface536and step faces696aand696bis located to be longitudinally inward from the outboard surface571. It is also noted that this requires that collar portions687aand687bsurround the head portion534and extend through the hole573in order for overhang surfaces689aand689bto engage the outboard surface571. Thus, the diameter575of hole573must be substantially larger than the diameter535of the head portion534, since it must also accommodate the additional offset distances703aand703bin addition to the diameter535of head portion534. This is in contrast to the embodiment ofFIGS. 6a-j, where the overlie engagement between transition surface392and end faces617aand617bis located to be longitudinally outward from the outboard surface571. InFIGS. 6a-g, the hole573does not need to be sized to accommodate this additional lateral offset geometry. Thus, in the embodiments ofFIGS. 6a-j, the diameter575of hole573may be comparatively reduced relative to the diameter398of head portion393, requiring only a clearance fit between diameters398and575. In contrast toFIGS. 6a-j, the larger diameter575of hole573and/or smaller diameter535of head portion534ofFIG. 8a-cresults in a reduced projected area of overlie engagement between transition surface536and step faces696aand696b(corresponding to higher stress at the overlie engagement) and/or a larger diameter575of hole573(corresponding to a weaker spoke bed568).

While shank portion532and head portion534are shown to be generally circular and concentric about the longitudinal axis37, shank portion532and/or head portion534may alternatively be noncircular and/or eccentric about the longitudinal axis37. In such a case, the reliefs691aand/or691band/or the necked openings697aand/or697bmay include corresponding noncircular geometry to provide a rotationally keyed engagement between the spoke530and the connector685.

The embodiment ofFIGS. 9a-cis exemplary to describe how the spoke may be secured to the connector by means of an integral joinder. For general definition purposes herein, an “integral” joinder is one that is integrated and may not be easily disassembled at the service temperature without damaging at least one of the components that are joined or is difficult to disassemble or is otherwise not meant to be disassembled. This integral joinder involves a joining interface directly between two components. This joining interface is often a welded or adhered interface or some other interface where the two joining surfaces are solidly joined to each other to create a unified structure. Preferably this joining interface is a surface interface, rather than a point interface. The integral joinder is in contrast to a fastened joinder, where such a fastened joinder relies solely on a mechanically interlocked engagement to secure or connect the two components to each other. The term “integral” refers to two portions that are unitary, monolithic and/or integrally joined. Further, when two portions are considered “integral” with each other, they may be integrally joined or may be monolithic or otherwise combined as a singular element.

Spoke700includes end portion701of diameter702. Spoke bed568is identical to that shown inFIGS. 5a-iand is shown in fragmentary view for illustration purposes and it is understood that spoke bed568constitutes a portion of the rim or hub flange to which the connector606is attached.

Connector705is composed of two segments706aand706b, each including associated flange portions710aand710b, collar portions707aand707b, enlarged portions708aand708b, and overhang surfaces709aand709brespectively. The opening712is created by cylindrical reliefs711aand711band extends along the opening axis713as shown.FIG. 9ashows segments706aand706bas collapsed and proximal to each other, with segment706acontacting segment706bas shown. In this collapsed orientation, the width720across enlarged portions708aand708bis sized to provide a close clearance fit with circular diameter575of hole573, allowing the connector705to be assembled within hole573. Segments706aand706bare then simultaneously inserted within hole573and advanced in direction715until overhang surfaces709aand709bclear past outboard surface571. Segments706aand706bare then opposedly spread in directions716aand716brespectively to achieve an expanded and distal orientation such that collar portions707aand707bare fully seated and nested against hole sidewall574as shown inFIG. 9b. Gaps714are thus created between segments706aand706band overhang surfaces709aand709bare now overlapping outboard surface571to create an overlie engagement between the segments709aand709band the spoke bed568. This embodiment is an example of “simultaneous” installation of segments708aand708bwithin spoke bed568. This is in contrast to the “sequential” installation of the segments described in some of the other embodiments herein, including the embodiment ofFIG. 5a-i. Alternatively, segments708aand708bmay be installed in hole573in a sequential manner similar to that described inFIGS. 6a-j.

Reliefs711aand711bare shown inFIG. 9bto be correspondingly spread to be distal from each other such that their combined geometry creates a generally cylindrical opening712of diameter718that is sized to receive the end portion701of spoke700. Next, uncured adhesive is applied to the surface of reliefs711aand711band to the surface of end portion701in preparation for assembly insertion of the spoke700into opening712.

Next, as shown inFIG. 9c, spoke700is inserted in opening712in direction717along the opening axis713such that end portion701extends through and within opening712as shown. The previously applied adhesive is now distributed on the surfaces of the end portion701and on reliefs711aand711b, thus creating adhesive interfaces719aand719bat the interfaces where these surfaces meet. Upon curing or hardening of the adhesive, the spoke700is securely joined to the connector705at the adhesive interfaces719aand719b, resulting in an integral joinder therebetween.

The diameter702of end portion701is a close fit with the diameter718of opening712, thus providing a bracing and blocking engagement between the reliefs711aand711bto limit the laterally proximal or inward movement of the segments706aand706band prevent the connector705from inadvertently achieving an unexpanded or collapsed orientation. The segments706aand706bare now locked in their expanded or open and spread orientation. Thus, the overlie engagement between the overhang surfaces709aand709band outboard surface571is now maintained, thereby locking the connector705to the spoke bed568. Further, it is anticipated that the adhesive may be applied in paste form and may serve to fill any clearance between diameters702and718. Additionally some adhesive may migrate into gaps714, thus providing a further bracing and blocking engagement between the segments706aand706bupon curing and solidification of the adhesive. The spoke700is now directly engaged to the connector705to resist spoke tension30forces along tensile axis36and to retain the spoke700to the spoke bed568. Thus, a blind connection between the spoke700and the spoke bed568is achieved. Further, the adhesive interfaces719aand719bextend longitudinally along the full length of the connector705, including the portion that is longitudinally outward of the outboard surface571. This serves to provide longitudinal reinforcement the connector705. This integral joinder also extends longitudinally outward of the outboard surface571as is preferable to join the spoke700adjacent the enlarged portions708aand708bto optimize stress distribution in the connector705associated with spoke tension30loads.

The embodiment ofFIGS. 9a-cshow a circular cylindrical interface between the end portion701and opening712. Alternatively, the interface may be a non-circular cylindrical interface. For example, the spoke may be flattened into an elliptical cross sectional profile in the region where it interfaces the opening712. The adhesive described in this embodiment may preferably be a paste adhesive, such as epoxy. However, a wide range of alternate adhesives, as known in industry, may be substituted. Further, it is noted that the spoke700is shown in this embodiment to be directly connected and engaged to the connector705. It is noted that such an integral joinder may alternatively be achieved between the connector and an intermediate connecting element in an indirect connection where the spoke is connected to the intermediate connecting element and the intermediate connecting element is connected to the connector.

The embodiment ofFIGS. 10a-bis identical to the embodiment ofFIGS. 5a-iin most respects. However,FIGS. 10a-bdescribe an exemplary embodiment where the opening axis741of the connector728is at a non-parallel angle744relative to the central axis569. Spoke100, sleeve86, and spoke bed568are identical to that described inFIGS. 5a-i.

Connector728is a multi-piece connector consisting of segments730aand730b, each include associated flange portions738aand738b, collar portions732aand732b, enlarged portions734aand734band overhang surfaces736aand736brespectively. Segments730aand730balso include semi-circular cylindrical reliefs740aand740b, with respective internal thread portions742aand742bthat extend along opening axis741. As particularly shown inFIG. 5a, collar portions732aand732bhave a width743across their external surfaces and enlarged portions734aand734bhave a width747across their outer surfaces, with overhang surfaces736aand736bhaving widths745aand745brespectively. Cylindrical reliefs740aand740bcombine to create opening746that extends longitudinally along the opening axis741through their flange portions738aand738b, collar portions732aand732b, and enlarged portions734aand734b, respectively.

FIG. 10acorresponds to the assembly sequence ofFIG. 5h. The connector728is assembled to the spoke bed568in a manner similar to that described inFIGS. 5a-i.FIG. 10bcorresponds to the assembly sequence ofFIG. 5i, with external threads88threadably engaged to internal threaded portions742aand742bin a manner similar to that described inFIGS. 5a-i. Longitudinal axis37is shown to be at angle744with respect to central axis569and is also non-orthogonal to inboard surface568and outboard surface571.

FIGS. 10a-bdescribe an embodiment where the opening axis741is at a non-parallel angle744to the central axis569of the spoke bed568. This angle744may be advantageous because it allows the hole573to be drilled at an angle that may not necessarily be aligned with the span of spoke100or with the tensile axis36. For example, if the spoke bed is a portion of the rim (not shown), the hole573may be drilled at straight radial direction, as is most common and as shown inFIGS. 5a-l, for example. Then, the angle744may be oriented such that the tensile axis36of the sleeve86and corresponding spoke100may be aligned to accommodate the bracing angle of the spoke span. In most bicycle wheel applications, it is preferable that this angle744is between 3 and 12 degrees. It is shown that angle744extends in a plane that is generally perpendicular to the plane of slot748. Alternatively, it is envisioned that angle744may extend in a plane that is generally parallel to the plane of slot748. Further, it is shown that slot748extends in a direction generally parallel to the opening axis741. Alternatively, the slot749may extend in any other direction.

The embodiment ofFIGS. 11a-bis identical to the embodiment ofFIGS. 5a-iin most respects. However,FIGS. 11a-bdescribe an exemplary embodiment where the hole773of spoke bed768is non-circular, with a length776greater than its width775.FIG. 11acorresponds to the assembly sequence ofFIG. 5a. The connector778is assembled to the spoke bed768in a manner similar to that described inFIGS. 5a-i.FIG. 11bcorresponds to the assembly sequence ofFIG. 5e, with external threads88threadably engaged to internal threaded portions792aand792bin a manner similar to that described inFIGS. 5a-i. Spoke100and sleeve86are identical to that described inFIGS. 5a-i.

Spoke bed768includes a radially outboard surface771, a radially inboard surface772. Spoke bed768also includes a non-circular hole773therethrough with hole sidewall774and with a length776greater than its width775. In this figure, the noncircular hole573has an oval profile with flats770along the width775. While this oval hole profile is merely representative of a wide range of possible noncircular hole profiles, the oval profile may be particularly preferable since it may be produced in a simple milling operation. Hole773extends along central axis769, which is shown here to be generally perpendicular to the outboard surface. Spoke bed768is shown in fragmentary view for illustration purposes and it is understood that spoke bed768constitutes a portion of the rim or hub flange to which the connector778is attached.

Connector778is a multi-piece connector consisting of segments780aand780b, each include associated flange portions788aand788bwith flats789, collar portions782aand782b, enlarged portions734aand734band overhang surfaces786aand786brespectively. Segments780aand780balso include semi-circular cylindrical reliefs790aand790b, with respective internal thread portions792aand792bthat extend along opening axis791. Cylindrical reliefs790aand790bextend longitudinally along the opening axis791through their flange portions788aand788b, collar portions782aand782b, and enlarged portions784aand784b, respectively. As shown inFIG. 11b, upon installation and expansion of segments780aand780bwithin hole773, gaps797are created between segments782aand782b. Also, the length793across enlarged portions784aand784bis now larger than the corresponding length776of hole773to create an overlie engagement between overhang surfaces786aand786band outboard surface771to support spoke tension30along tensile axis36.

It is noted that collar portions782aand782bare not semi-circular in profile, but instead include flats783and are semi-oval shaped to match with the oval hole773. It may be seen that width785across flats783corresponds to width775across flats770such that, upon subsequent installation of segments780aand780bas shown inFIG. 11b, flats783are engaged with flats775in a rotationally keyed engagement about the central axis769. Thus, connector778is correspondingly rotationally keyed to the spoke bed768. This arrangement may be advantageous since it may be used to control the rotation of the connector778relative to the spoke bed768. Additionally, such a noncircular hole may permit a corresponding additional thickness of the collar portion(s)782aand/or782b, thus advantageously imparting additional robustness of the connector778.

The embodiment ofFIGS. 12a-cis identical to the embodiment ofFIGS. 5a-iexcept for the inclusion of an additional spacer750element. Spoke100, spoke bed568, connector578and sleeve86are all identical to those shown inFIGS. 5a-i. Spacer570includes a circular base portion752with central hole753therethrough. Extensions755aand755bextend from the base portion752and include enlarged portions756aand756band overhang surfaces757aand757band inner surfaces759aand759brespectively.

FIG. 12acorresponds to the assembly sequence ofFIG. 5dandFIG. 12ccorresponds to the assembly sequence ofFIG. 5e. The connector578is installed within the spoke bed568in a manner previously described inFIGS. 5a-i. With segments580aand580binstalled within the hole573as described inFIGS. 5a-i, the spacer750is then installed in direction760in the connector578, with extension755ainserted within gap597aand755binserted within gap597b. During installation, the extensions755aand755bmay be flexed laterally proximal or inwardly to permit enlarged portions756aand756bto clear through the hole573. When the spacer750is advanced in direction760until overhang surfaces757aand757bare aligned with outboard surface571, the extensions755aand755bmay now spring back apart, with overhang surfaces757aand757overlapping the outboard surface571in an overlie engagement as shown inFIG. 12c. With extensions755aand755bpositioned within gaps597aand597b, these gaps are now essentially plugged and filled by the extensions755aand755b, thus providing a bracing and blocking engagement between the segments580aand580bto limit their laterally proximal or inward movement and thus preventing the connector578from inadvertently achieving an unexpanded, proximal or collapsed orientation. The segments580aand580bare now locked in their expanded, distal or open and spread orientation relative to each other. Thus, the overlie engagement between the overhang surfaces586aand586band the outboard surface571is now maintained by the spacer750, thereby locking and engaging the connector578to the spoke bed568.

Next, the sleeve86and spoke100are passed through the opening596in direction760and external threads88are threadably mated to internal threads592aand592bin a similar manner to that described inFIGS. 5a-iand shown inFIG. 12c. Sleeve86serves as bracing and blocking engagement between inner surfaces759aand759bof extensions755aand755bto further lock them in their expanded orientation relative to each other. Thus, the overlie engagement between the overhang surfaces586aand586band the outboard surface571is now further maintained by the sleeve86, thereby locking and engaging the connector578to the spoke bed568. Inner surfaces759aand759bare shown inFIG. 12bto have a serrated surface to be matched with the external threads88of sleeve86. Thus, serrations of inner surfaces759aand759bmay interlock and engage with external threads88to further lock the spacer750to the spoke bed568. The connections and engagements between the spoke100, the sleeve86, the spacer750, the connector578, and the spoke bed568serve to effectively join the spoke100to the spoke bed568to resist spoke tension30.

The embodiment ofFIGS. 13a-dis virtually identical to the embodiment ofFIGS. 5a-iexcept for the substitution of segment580cfor segment580b. Spoke bed568spoke100, and sleeve86are all identical to those shown inFIGS. 5a-i. Segment580ais generally identical to that shown inFIGS. 5a-i. Segment580cis similar to segment580b, with the exception that segment508cdoes not include an enlarged portion or an overhang surface. Segment580cincludes flange portion588c, collar portion782c, and semi-circular cylindrical relief590cwith internal thread portion592cthat extends along opening axis591. Cylindrical relief790cextends longitudinally along the opening axis591through flange portion588cand collar portion582c. Connector602is a multi-piece connector consisting of segments580aand580c.

FIG. 13acorresponds to the assembly sequence ofFIG. 5fandFIG. 13bcorresponds to the assembly sequence ofFIG. 5gandFIG. 13ccorresponds to the assembly sequence ofFIG. 5handFIG. 13dcorresponds to the assembly sequence ofFIG. 5i. Segment508ais first installed within the hole573of spoke bed568as previously described inFIGS. 5a-iand as shown inFIG. 13b. It is noted that, as segment580ais inserted through hole573, with enlarged portion584aligned with hole sidewall574, segment580ais in a laterally contracted orientation that is proximal to segment580c. Then, when segment580ais shifted in direction598a, it achieves a laterally expanded orientation that is laterally distal to segment580c.

Next, segment580cis advanced in direction599cthrough hole573until flange portion588cabuts the inboard surface572of the spoke bed568as shown inFIG. 13c. Internal thread portion592cis now aligned with internal thread portion592aalong the opening axis591to achieve an internally threaded opening596to receive external threads88of collar86.FIGS. 13b-cdescribe a sequential installation of segments580aand580c. It is noted that, since segment580chas no enlarged portion or laterally extending overhang surface, it does not need to laterally collapse or laterally expand during installation. Therefore, segment580cmay be sized such that it fills the remainder of the perimeter of hole573that is left over after the first assembly step of the installation of segment580a. As such, upon installation of segment580cin a second step, as shown inFIG. 13c, segment580claterally abuts segment580a, with collar portion584cnested with hole sidewall574. Since segment580cdoes not need to achieve a collapsed or expanded orientation, there is also no gap between segments580aand580c. Further, segment580cnow provides a bracing and blocking engagement between the hole573and segment580ato limit the laterally proximal movement of segment580aand thus preventing the connector602from inadvertently achieving an unexpanded, proximal or collapsed orientation. The segment580ais now locked in its laterally expanded, distal or open and spread orientation. Thus, the overlie engagement between the overhang surface586aand the outboard surface571is now maintained, thereby locking and engaging the segment580ato the spoke bed568.

Next, the sleeve86(with spoke100) is threadably installed through the opening596, with external threads88threadably mated to internal threads592aand592cin a similar manner to that described inFIGS. 5a-iand shown inFIG. 13d. Sleeve86serves as an additional bracing and blocking engagement between segments580aand580bto further lock them in their expanded orientation relative to each other and limit their proximal movement. Thus, the overlie engagement between the overhang surfaces586aand586band the outboard surface571is now further maintained by the sleeve86, thereby locking and engaging the connector602to the spoke bed568. Further, with external threads88engaged to both internal thread portions592aand592b, segment580cis longitudinally engaged to segment580aalong the opening axis591and is thereby also engaged to the spoke bed568. The connections and engagements between the spoke100, the sleeve86, the connector602, and the spoke bed568serve to effectively join the spoke100to the spoke bed568to resist spoke tension30along tensile axis36.

While the previous embodiments have shown connectors as being composed of two segments, it may be advantageous to have the connector as composed of three or more segments.FIG. 14describes an embodiment where the connector808is composed of three segments810a,810b, and810cand is exemplary of a connector that is composed of more than two segments. Spoke bed568is identical to that described inFIGS. 5a-iand is shown in phantom for better clarity. The segments810a,810b, and810care very similar to segments580aand580bofFIGS. 5a-iandFIG. 14corresponds to the assembly/installation sequence ofFIGS. 5dand5h.

Connector806is composed of three segments (810a,810b, and810c), each including associated flange portions (818a,818b, and818c), collar portions (812a,812b, and812c), enlarged portions (814a,814b, and814c), end faces (824a,824b, and824c) and overhang surfaces (816a,816b, and816c) respectively. The opening819is created by cylindrical reliefs (820a,820b, and820c) with internal threaded portions (822a,822b, and822c) and extends along the opening axis821as shown.

With the connector806as shown in its expanded configuration gaps (823a,823b, and823c) are created between segments (810a,810b, and810c) and overhang surfaces (816a,816b, and816c) are now overlapping outboard surface571to create an overlie engagement between the connector806and the spoke bed568. It is noted that gaps (823a,823b, and823c) are tapered to have a greater width825at their longitudinally outward end adjacent end faces (824a,824b, and824c) and a narrower width826at their longitudinally inward end adjacent flange portions (818a,818b, and818c). These tapered gaps permit the enlarged portions (814a,814b, and814c) to be collapsed to a greater degree during their previous installation through hole573, while minimizing the width826of the exposed portion of the gaps (823a,823b, and823c) adjacent the flange portions (818a,818b, and818c). This greater degree of collapse may permit simultaneous installation of two or more of the segments (810a,810b, and810c) as described previously. Otherwise, these segments may be installed sequentially as previously described. Upon installation of segments as shown, a spoke (not shown) or sleeve (not shown) may be threadably connected to the opening816in a manner similar to that described inFIGS. 5a-i.

The embodiment ofFIGS. 15a-gis similar to that ofFIG. 6a-j, howeverFIGS. 15a-gshow segments that are installed simultaneously. Also, instead of the parallel expansion (as in directions625aand625b) of segments608aand608b, segments840aand840bare expanded by an angular splaying as described inFIGS. 15a-f. Further, instead of the shank portion388of nipple386providing the blocking engagement of segments608aand608b, it is the head portion893of nipple886that provides the blocking engagement to lock segments840aand840bin their expanded orientation.

Spoke394and spoke bed568are identical to those described inFIGS. 6a-j. Spoke nipple886includes a shank portion888, an enlarged head portion893with a cylindrical surface895of diameter894, a flange897with flange face898. Laterally projecting transition surface892extends between head portion893and shank portion888. Shank portion888also includes flats89such that it may be manually manipulated with a wrench (not shown). Transition surface892is shown here to be a generally planar and laterally projecting surface, extending perpendicular to the longitudinal axis37. Nipple886also includes longitudinal hole890therethrough with internal threads891to threadably mate with external threads395of spoke394. Nipple886also includes flange897with longitudinally outward flange face898. The spoke394is shown inFIG. 15ato be threadably preassembled to the nipple886, with external threads395mated to internal threads891and with the end portion396extending within the hole890along the longitudinal axis37.

Spoke bed568is shown in fragmentary view for illustration purposes and it is understood that spoke bed568constitutes a portion of the rim or hub flange to which the connector838is attached. Connector838is a multi-piece connector consisting of segments840aand840b, each include associated flange portions848aand848bwith flats856, collar portions842aand842b, enlarged portions844aand844b, end faces847aand847b, and overhang surfaces846aand846brespectively. The opening852is created by counterbore portions855aand855band smaller necked openings858aand858b, with lateral step faces854aand854bextending therebetween respectively. Segments840aand840balso include gap faces859aand859brespectively.

As shown inFIGS. 15a-b, segments840aand840bare aligned to be preassembled to the nipple886, with gap faces859aand859baligned to be generally parallel to each other and extending generally parallel to the longitudinal axis37. As shown inFIG. 15c, segments840aand840bare moved in directions861aand861brespectively until the shank portion888is nested within necked openings858aand858bto create the preassembly857of segments840aand840b, and nipple886. Although they are obscured in the section view ofFIG. 15c, gap faces859aare now meeting and abutting against gap faces859b. Segments840aand840bare in a collapsed and laterally proximal orientation relative to each other. Step faces854aand854bare generally orthogonal to respective cylindrical counterbore portions855aand855b, which are at angle862relative to the longitudinal axis37. End faces847aand847bare longitudinally abutting transition surface892and flange portions848aand848bare longitudinally adjacent flange face898. It is noted that the cylindrical enlarged portions844aand844bare aligned to fit within a projected lateral envelope that generally corresponds with the diameter894of cylindrical surface895such that this entire preassembly857of connector838and nipple886may now be fitted through hole73.

Next,FIG. 15dshows the initiation of a second assembly/installation step where the preassembly857is being installed within hole573in direction863, with diameter894sized to fit through hole573. Cylindrical surface895and enlarged portions844aand844bare shown to be overlapping hole sidewall574along the central axis569. Next, the preassembly857is fully advanced in direction863until the flange portions848aand848babut inboard surface572and overhang surfaces846aand846bare aligned to be just beyond outboard surface571. Segments840aand840bmay now be splayed in directions864aand864bby splay angle865to achieve an expanded and laterally distal orientation relative to each other as shown inFIG. 15e. In this expanded orientation, overhang surfaces846aand846bare now overlying, hooking and engaged to outboard surface571. Step faces854aand854bare now generally orthogonal to the longitudinal axis37and semicylindrical counterbore portions855aand855bcombine to achieve a generally cylindrical cavity that extends to be generally parallel to longitudinal axis37. The opening852between segments840aand840bis correspondingly expanded to include counterbore portions855aand855band necked openings858aand858band gaps853extending along opening axis851. Also, it may be seen that the flange portions848aand848bcombine to create a generally square and noncircular profile that includes flats856such that it may be manually manipulated with a wrench (not shown).

Spoke394and nipple386are next drawn in direction866, in a third installation step, until the transition surface892abuts step faces854aand854bas shown inFIG. 15f. Cylindrical surface895is now longitudinally overlapping and nested within counterbore portions855aand855b. With segments840aand840bopposed and fully seated as shown, the connector838is considered to be open, spread or laterally expanded, such that gaps853are created between the two. These gaps853are necessary to provide the requisite clearance to allow segment840bto be collapsed against segment840aand to permit enlarged portions844aand844bto clear the hole573during the previous second installation step.

It is noted that segments840aand840bare angularly expanded and splayed in non-parallel and arcuate directions864aand864bduring their expansion as shown. Correspondingly, gaps853are generally tapered and wedge-shaped, as shown inFIG. 15g, with a narrower gap853portion adjacent the flange portions848aand848band a wider gap853portion adjacent end faces847aand847b. In contrast, the segments608aand608bofFIGS. 6a-jremain generally parallel during their expansion as shown and are laterally expanded in a generally opposed linear direction625aand625b, with a generally straight gap627between the two.

The diameter894of head portion893is a close fit between counterbore portions855aand855bwhile the connector838is in its expanded, splayed, or open orientation, thus providing a bracing and blocking engagement between the segments840aand840bto limit their laterally proximal or inward movement and preventing the connector838from inadvertently achieving an unexpanded or collapsed orientation. The segments840aand840bare now locked in their expanded and spread orientation. Thus, the overlie engagement between the overhang surfaces846aand846band outboard surface571is now maintained, thereby locking the connector838to the spoke bed568.

Further, the laterally projecting transition surface892now has an overlie engagement with step faces854aand854band the nipple886is thus engaged to the connector838to resist spoke tension30forces along tensile axis36and to retain the spoke394to the spoke bed568. It should be noted that the nipple886serves as an intermediate connecting element between the spoke394and the connector838to effectively join the spoke394to the spoke bed568to resist spoke tension30. Thus, a blind connection between the spoke394and the spoke bed568is achieved. Spoke tension may be adjusted in the conventional manner, with nipple886rotated (via flats889) independently of the spoke394about the longitudinal axis37to threadably adjust the engagement between internal threads891and external threads395. Further, the nipple886may be rotated independently of the connector838about the opening axis851, and the connector838may be held stationary during this adjustment by means of a wrench (not shown) engaged with flats856. The spoke overlie engagement between transition surface892and step faces854aand854bis oriented longitudinally outwardly (by offset distance899) from the connector overlie engagement between overhang surfaces846aand846band outboard surface571. As described previously, this longitudinally outward extending offset distance899is preferable to the spoke overlie engagement and connector overlie engagement being oriented longitudinally coincident or to the spoke overlie engagement being oriented longitudinally inward of the connector overlie engagement.

While my above description contains many specificities, these should not be construed as limitations on the scope of the invention, but rather as exemplifications of embodiments thereof. It is to be understood that the invention is not limited to the illustrations described and shown herein, which are deemed to be merely illustrative of the best modes of carrying out the invention, and which are susceptible of modification of form, size, and arrangement of parts and details of operation. For example:

While the embodiments shown herein show a connector consisting of two discreet segments, the connector may alternatively consist of three or more discreet segments.

While it is shown in many of these figures that the central axis of the opening of the connector is generally collinear with the central axis of the corresponding hole in the spoke bed, the central axis of the opening may alternatively be offset (i.e. eccentric) or may be at a nonparallel angle with respect to the central axis of the corresponding hole. Further, while it is shown in many of these figures that the central axis of the opening of the connector is generally collinear with the tensile axis36of the spoke span, the central axis of this opening may alternatively be at an angle to the tensile axis36. In such a case, the spoke may be bent or deflected such that its longitudinal axis is aligned with the opening.

The sleeve and/or nipple may be regarded as an intermediate component in the connection between the spoke and the connector. In other words, the spoke connects to the sleeve and/or nipple, the sleeve and/or nipple connects to the connector, and the connector connects to the rim or hub. Further, there may alternatively be additional intermediate components inserted in this chain of connection.

These figures show the connector component to include a flange located externally and longitudinally inward relative to the hole to which the connector is assembled. Such a flange may be useful in creating an external overlie engagement with the inboard surface of the spoke bed to control positioning of the connector and also prevent the connector from inadvertently being pushed clear through the hole. However, it should be recognized that the primary engagement of the present invention is the engagement to resist spoke tension, which is in the opposite direction to the overlie engagement of the flange. Therefore, the flange may provide a desirable convenience to aid in the assembly and/or retention of the ferrule but may not be a requirement for proper function of some or all of the embodiments described herein. The present invention may still be functional without incorporating an external flange of the connector.

The connector component may remain stationary with respect to spoke bed, while the sleeve and/or the spoke may be rotated about the longitudinal axis. Alternatively, the connector component may be permitted to rotate relative to the spoke bed. If desired, this would allow the connector to rotate and slip at its interface with the spoke bed.

The embodiments described herein show a hole in the spoke bed that is generally circular about the central axis as well as segments with generally circular cylindrical collar portions. This circular hole may be preferable, since such a hole may be easily achieved in a simple drilling operation. However, the hole in the spoke bed may alternatively be non-circular about the central axis. Further, the collar portion(s) of the connector may have projections or reliefs or other non-circular geometry. Still further, the noncircular geometry of the connector may mate with the noncircular hole of the spoke bed for a rotationally keyed engagement about the central axis and/or about the longitudinal axis.

Several of the embodiments described herein also show a spoke bed with generally flat inboard and outboard surfaces. Alternatively, the inboard and/or outboard surface of the spoke bed may be non-flat and employ a configured surface with projections and/or recesses. Further, the overhang surface(s) and/or flange of the connector may have non-flat geometry where these portions contact the spoke bed. Still further, the non-flat geometry of the overhang surface(s) and/or flange of the connector may mate with the non-flat geometry of the inboard and/or outboard surface of the spoke bed. Such mating of non-flat surfaces may provide a rotationally keyed engagement between the connector and the spoke bed about the central axis and/or about the longitudinal axis.

While the embodiments shown herein show the segments of the connector as relatively rigid elements that do not flex appreciably during assembly or operation. However, one or more of the segments may be designed to flex or distort during assembly or during operation. For example, one of the segments may be designed to flex slightly as it is inserted though the hole in the spoke bed during assembly and then spring back to its original form once it has been fully inserted. This flexure may serve to provide additional clearance for insertion of the segment.

The embodiments described herein show a blind connection with a blind hole through which the connector is connected. However the present invention may prove to be advantageous to achieve such a blind connection even in arrangements where the hole itself is not a blind hole and there is access to both ends of the hole.

While the embodiments described herein show a surface-to-surface overlie engagement between a surface of the spoke and a surface of the connector, it is also envisioned that this overlie engagement may include a surface-to-edge engagement, where the spoke or the connector includes an engagement edge that has an overlie engagement with a surface of the other of the spoke or connector.

The embodiments described herein show the spoke as connected to the connector via a connection between the spoke and both segments (i.e. the full complement of segments) of the connector. However it is envisioned that the spoke may alternatively be connected to only one of the segments (i.e. less than the full complement of segments).

The embodiments described herein show the each segment of the connector to include an overhang surface to engage the spoke bed. Alternatively, one (or more) of the segments may not include an enlarged portion and/or an overhang surface to engage the spoke bed. However, at least one of the segments must include the requisite overhang surface to engage the spoke bed. Further, many of the embodiments described herein show a connector with all of its overhang surfaces coinciding with a generally common plane. It is envisioned that the multiple overhang surfaces of a single connector may be offset from each other along the longitudinal axis and may correspond to different longitudinal heights.

Accordingly, the scope of the invention should be determined not by the embodiments illustrated, but is instead intended to encompass all such modifications that are within its spirit and scope as defined by the claims.