Abstract:
A wheel with flexible spokes, including a rim and hub, and spokes between the rim and hub made of fibrous material that causes the spokes to be both lighter in weight and stronger than comparable steel spokes. The spokes are also flexible and resilient such that they can bend while retaining their integrity and strength.

Description:
RELATED APPLICATION 
       [0001]    This application claims the benefit of priority and is a continuation-in-part Application to co-pending U.S. Utility application Ser. No. 13/487,253 filed Jun. 4, 2012, entitled “Wheel With Flexible Wide-Body Spokes”. 
     
    
     FIELD OF INVENTION 
       [0002]    The present invention is directed to vehicular wheels having high-strength and light-weight spokes, particularly bicycle, motorcycle, and wheelchair wheels. 
       BACKGROUND OF INVENTION 
       [0003]    The most common construction for bicycle wheels includes spokes made of stainless steel or other metal. While stainless steel is strong, it is also heavy. Therefore, the spokes must be made as thin as possible to make them as light as possible. However, the thinner the spoke, the less strength it has. The thicker the spoke, the stronger it is. Therefore, in making spokes of steel, there is a tradeoff between making the spokes strong and making them lightweight. Thus, there is a need for a wheel with spokes that can be both lightweight and strong without having to deal with this tradeoff between the two. Another problem with steel spokes is that, if they are bent, they weaken and ultimately fail such that they must be replaced if bent. 
         [0004]    One solution to this problem was presented in U.S. Pat. No. 5,110,190 which issued to Harold Johnson on May 5, 1992, for an invention entitled “High Modulus Multifilament Spokes And Method” (hereinafter the &#39;190 patent). The &#39;190 patent is fully incorporated herein by this reference. The &#39;190 patent discloses a high modulus multifilament non-rigid and rigid wheel spoke that includes a fiber mid-portion between a first and second end having attachment members affixed thereto. The &#39;190 patent also discloses methods of supporting a hub within a wheel rim by means of a plurality of spokes or by means of continuous lengths of spokes. 
         [0005]    While the device presented in the &#39;190 patent clearly made advancements over the state of the art at that time, the device nevertheless has its shortcomings. For instance, the small diameter of the filament spokes requires that the spokes be maintained in a substantially axial arrangement with its connectors. This, unfortunately, makes the manufacturing of wheels incorporating the &#39;190 technology more difficult due to the of off-axis tension. Specifically, even though the spokes of the &#39;190 patent are orders of magnitude stronger than their metallic counterparts, the strength of the &#39;190 spokes is slightly decreased from its maximum strength due to the bend in the spokes as they leave the wheel rim when installed in a wheel. 
         [0006]    U.S. Pat. No. 6,036,281 which issued on Mar. 14, 2000, to Richard Campbell and entitled “Low Rotational Mass Bicycle Wheel System” (hereinafter the &#39;281 patent), disclosed a bicycle wheel system having spokes extending radially from hub to spoke. The spokes are provided with fittings at its rim end which are constructed with minimal mass and fittings at the hub end which allow adjustment of the tension of the spoke. The spokes are constructed of a bundle of liquid crystal fibers having no significant creep surrounded by an extruded plastic jacket. 
         [0007]    While the spoke presented in the &#39;281 patent certainly represents a milestone in bicycle wheel technology and light-weight wheel manufacturing, it nevertheless has its challenges with implementation. First of all, there are manufacturing challenges in keeping the spokes aligned with their connectors. In narrow-width wheel applications, the device disclosed in the &#39;281 are difficult to install as the alignment is important. This alignment results in increased assembly costs and overall product costs. 
         [0008]    The present invention resolves these problems by providing spokes that are both lighter in weight than steel and significantly stronger than steel, and that are flexible such that they can bend without suffering damage. Moreover, due to their significant strength and durability, fewer numbers of spokes are required on wheels while still providing a lightweight wheel with superior strength. Further, the addition of aerodynamic jackets over the spoke work to reduce drag as the spoke rotates during use. 
       SUMMARY OF THE INVENTION 
       [0009]    The wheel with flexible wide-body spokes of the present invention provides the aforementioned advantages by providing a wheel including a rim and hub, and spokes between the rim and hub made of fibrous material that causes the spokes to be both lighter in weight and stronger than comparable steel spokes. The spokes are also flexible and resilient such that they can bend while retaining their integrity and strength. Further, an aerodynamic cover is formed over the fibrous material 
     
    
     
       BRIEF DESCRIPTION OF DRAWINGS 
         [0010]    The aforementioned and other advantages of the wheel with flexible spokes of the present invention will become more apparent to those skilled in the art upon making a thorough review and study of the following detailed description of the invention when reviewed in conjunction with the drawings in which like references numerals refer to like parts, and wherein: 
           [0011]      FIG. 1  is a side view of a first preferred embodiment of the wheel with flexible spokes of the present invention, showing the rim, hub, spokes between rim and hub, tubes attaching each spoke to the rim, and anchors attaching each spoke to the hub; 
           [0012]      FIG. 2  is a rear detail view of the first preferred embodiment of the wheel with flexible spokes of the present invention, showing the hub, the angle between spokes on the left side of the wheel and spokes on the right side of the wheel, and the angle of the hub surface at the point of attachment of each spoke to the hub; 
           [0013]      FIG. 3  is a cross-sectional view of the first preferred embodiment of the wheel with flexible spokes of the present invention, taken across line  3 - 3  of  FIG. 1 , showing cross-sectional portions of the rim and hub, and showing how each tube attaches each spoke to the rim via a nipple in the rim, and how each anchor attaches each spoke to the hub; 
           [0014]      FIG. 4  is a cross-sectional view of the first preferred embodiment of the wheel with flexible spokes of the present invention, taken across line  4 - 4  of  FIG. 1 , showing a cross-sectional view of the fibers and jacket of one of the spokes; 
           [0015]      FIG. 5  is a cross-sectional view of the first preferred embodiment of the wheel with flexible spokes of the present invention showing cross-sectional portions of the rim and hub, and showing how each tube, once attached to the rim, would extent away at an angle from the nipple in the rim; 
           [0016]      FIG. 6  is a side view of an alternative embodiment of the wheel with flexible spokes of the present invention showing a flexible spoke formed with a jacket having an aerodynamic tear-drop shape; 
           [0017]      FIG. 7  is a cross-sectional view of a flexible spoke of the present invention as taken through line  7 - 7  of  FIG. 6  having a jacket over the central fibers formed in an aero-dynamic teardrop shape; 
           [0018]      FIG. 8  is a cross-sectional view of a flexible spoke of the present invention having a jacket formed over the central fibers in an aero-dynamic oblong shape; 
           [0019]      FIG. 9  is a cross-sectional view of a flexible spoke of the present invention having a jacket formed over the central fibers in an aero-dynamic shape having a pointed leading and trailing edge; and 
           [0020]      FIG. 10  is a perspective view of a mold used to form the jacket in a desired shape around the central fiber bundle; 
           [0021]      FIG. 11  is a perspective view of an alternative heated mold used to form a jacket having two different cross-sections; 
           [0022]      FIG. 12  is a perspective view of the alternative heated mold in  FIG. 11  closed around a spoke blank; 
           [0023]      FIG. 13  is a perspective view of the alternative heated mold after separating the pieces of the mold to show a spoke having two different cross-sections. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0024]    Referring to  FIG. 1 , a side view of a first preferred embodiment of the wheel with flexible spokes of the present invention is shown and generally designated  100 . In  FIG. 1 , the side of wheel  100  facing the viewer can be referred to as the right side of the wheel  100 . The side of wheel  100  opposite the right side can be referred to as the left side of the wheel  100 . The wheel  100  has a wheel axis  104 , and a rim  110  which has an inner perimeter  112  and an outer perimeter  114 . Direction  102  is the preferred direction of rotation of wheel  100  however it is to be appreciated that wheel  100  is free to rotate in the direction opposite direction  102 . 
         [0025]    Still referring to  FIG. 1 , with reference to  FIG. 3 , distributed symmetrically along inner perimeter  112  are spoke holes  120 . Each spoke hole  120  has a spoke hole width  122 . Along the outer perimeter  114  are nipple access holes  124  (not visible in  FIG. 1 , see  FIG. 3 ), one nipple access hole  124  adjacent each spoke hole  120 . Wheel  100  further includes a hub  130  having a right flange  132  and a left flange  134  (not visible, behind right flange  132 ). Each flange  132  and  134  has an inner surface  136  and an outer surface  138 . In each flange  132  and  134  are flange holes  140 , each flange hole  140  corresponding to a unique spoke hole  120 . Each flange hole  140  has an inner opening  142  in the corresponding inner surface  136 , and an outer opening  144  in the corresponding outer surface  138 . Hub  130  also has a barrel  148  which receives an axle of a bicycle. 
         [0026]    Wheel  100  further includes non-rigid spoke members, or spokes  150 . Each spoke  150  has non-rigid fibers  152  (not visible this Figure) covered by a jacket  154  having an inner diameter  156  (not visible) and an outer diameter  158  which is also the width  158  of spoke  150 . Each spoke  150  has a length  160 . Fibers  152  are substantially continuous along the length  160  of spoke  150  Alternatively, one or more of fibers  152  may be less than continuous along the length of spoke  150 . Each spoke  150  has an inner end  162  adjacent hub  130 , and an outer end  164  adjacent rim  110 . Each spoke  150  has a tube  170  about its outer end  164 , and each tube  170  is formed with a tapered bore  171  opening away from the tube axis  172  of the spoke  150 . Each tube  170  is affixed to its corresponding outer end  164  by inserting the fibers  152  into the tube  170 , and filling the tube  170  with epoxy  163 . Once hardened, the epoxy  163  and fibers  152  form a wedge within the tapered bore  171  such that any tension on the spoke  150  draws the hardened wedge against the taper thereby securing the fiber within the tube  170 . Alternatively, tube  170  may be affixed to outer end  164  by any other material of similar strength. Tube  170  may be equipped with a hexagonal, reinforced head  165  which provides for added strength at the rim-end  164  of the tube  170 . This is helpful in preventing breakage from non-axial tension on spoke  150 , and facilitates the tightening of spoke  150 . 
         [0027]    Each tube  170  has a tube axis  172  and external spoke threads  174 . Each spoke  150  also has an anchor (or eyelet or ferrule)  180  about its inner end  162 . Each anchor  180  is formed with a tapered bore  181  opening away from the tube axis  172 . Each anchor  180  is affixed to its corresponding inner end  162  by inserting the fibers  152  into the anchor  180 , and filling the tapered bore  181  with epoxy  163 . Once hardened, the epoxy  163  and fibers  152  form a wedge within the tapered bore  181  formed in the anchor  180  such that any tension on the spoke  150  draws the hardened wedge against the tapered bore  181  thereby securing the fiber  150  within the anchor  180 . Alternatively, anchor  180  may be affixed to inner end  162  by any other material of similar strength. 
         [0028]    Each flange hole  140  is wider than spoke  150  but narrower than anchor  180 , such that tube  170  about outer end  164  can be passed into inner opening  142  and out of outer opening  144 , and such that the rest of spoke  150  can then be passed through flange hole  140  until anchor  180  comes into contact with inner surface  136  around inner opening  142 , which causes inner end  162  to be retained in flange hole  140  by anchor  180 . 
         [0029]    Wheel  100  also includes nipples  190 . One nipple  190  is shown in  FIG. 1  in broken line, inside rim  110 . There is a nipple  190  between each spoke hole  120  and its corresponding nipple access hole  124 . Each nipple  190  has a nipple opening  192 , nipple threads  194  inside nipple opening  192 , a collar  196 , and a nipple head  198 . Once each spoke  150  is passed through flange hole  140  until anchor  180  comes into contact with inner surface  136  around inner opening  142 , tube  170  is positioned and threaded into the corresponding nipple  190  via inter-engagement of spoke threads  174  with nipple threads  194 . This causes tube  170  to be retained in nipple  190  such that tube axis  172  is perpendicular to wheel axis  104  (shown in  FIG. 1 ). The retention of tube  170  in nipple  190  and of inner end  162  in flange hole  140  by anchor  180  causes spoke  150  to be held taut between rim  110  and hub  130 . 
         [0030]      FIG. 1  shows eight (8) spokes  150  attached to right flange  132 , and eight (8) spokes  150  attached to left flange  134  (not visible, behind right flange  132 ), for a total of sixteen (16) spokes  150 . Wheel  100  may alternatively have more or fewer than sixteen (16) spokes  150 . For example, wheel  100  may have twelve (12) spokes  150 , six (6) spokes  150  attached to each of flanges  132  and  134 . While it is also possible to have different numbers of spokes  150  attached to each of flanges  132  and  134 , having the same number of spokes attached to each of flanges  132  and  134  balances the load on the flanges  132  and  134 . 
         [0031]      FIG. 2  is a rear view of hub  130 .  FIG. 2  shows the angle  250  that one of the spokes  150  is attached to right flange  132 , and the corresponding angle  250  that one of the spokes  150  is attached to left flange  134 . In  FIG. 2 , the right side of wheel  100  is on the right side of  FIG. 2 , and the left side of wheel  100  is on the left side of  FIG. 2 , Broken line  230  in  FIG. 2  represents a plane  230  that bisects wheel  100  between the right side and left side of wheel  100 . Plane  230  is perpendicular to wheel axis  104 . Each outer surface  138  has the shape of a conical section that has an angle  240  to wheel axis  104 . Each spoke  150  extends perpendicularly from the corresponding outer surface  138 . Therefore, each spoke  150  extends from outer surface  138  at an angle  250  to plane  230 . This means that the magnitude of angle  260  between spoke  150  attached to right flange  132  and spoke  150  attached to left flange  134 , is twice the magnitude of angle  250 . 
         [0032]      FIG. 3  shows a partial cross-sectional detail view of a spoke  150  with its inner end  162  retained in flange hole  140  by anchor  180 , and tube  170  about to be received in nipple  190  in rim  110 .  FIG. 3  shows how nipple  190  is retained in spoke hole  120 . Spoke hole width  122  allows the portion of nipple  190  around nipple opening  192  to pass through spoke hole  120 , but does not allow collar  196  to pass through spoke hole  120 , such that nipple is retained in spoke hole  120  by the tension of spoke  150  on nipple  190  once tube  170  is threaded into nipple  190 .  FIG. 3  also shows spoke threads  174  which inter-engage with nipple threads  194  in thread tube  170  into nipple  190 . With tube  170  retained in nipple  190 , tube axis  172  is perpendicular to wheel axis  104  (not shown, see  FIG. 2 ) and intersects the corresponding spoke hole  120 . Spoke holes  120  lie in plane  230 . While spoke holes  120  may alternatively be adjacent plane  230 , spoke holes  120  being in plane  230  causes the forces of spokes  150  to be placed on rim  110  where plane  230  intersects rim  110 , which is the middle of the inner perimeter  112  of rim  110 . With spoke holes  120  in plane  230 , and each tube  170  received in the corresponding nipple  190 , tube axis  172  also lies in plane  230 . 
         [0033]    In  FIG. 3 , tube axis  172  coincides with the broken line representing plane  230 . However, because each spoke  150  extends at angle  250  to plane  230 , each spoke  150  extends from its tube  170  at angle  250  to tube axis  172 . This means that there is a bend in spoke  150  at an angle  250  at the point  320  where spoke  150  protrudes from tube  170 . With steel spokes, such a bend would weaken the spoke and ultimately cause the spoke to fail. However, with spokes  150 , such a bend does not damage spokes  150 , because fibers  152  are flexible and resilient yet strong such that spokes  150  retain their integrity and strength even when bent under tension in the manner described. Therefore, spokes  150  can bend without weakening or failing. Furthermore, each of spokes  150  is three times as strong, and weighs half as much, as a steel spoke that would otherwise be used in its place. This allows the width  158  of each of spokes  150  to be greater than that of a steel spoke that would be used in its place. In the alternative, the width  158  of each spoke  150  may be less than or equal to the width of a steel spoke that would be used in its place; the strength of each of spokes  150  may be greater or less than three times that of a steel spoke that would be used in its place; and the weight of each of spokes  150  may be greater or less than half that of a steel spoke that would be used in its place. 
         [0034]    Rim  110 , hub  130 , tube  170 , anchor  180  and nipple  190 , in a preferred embodiment, are made of aluminum. Alternatively, any of rim  110 , hub  130 , tube  170 , anchor  180  or nipple  190  may be made of any other material of comparable strength. In a preferred embodiment of the present invention, fibers  152  are a bundle of thermotropic liquid crystal fibers that exhibit high strength, low creep, and weather resistance. For instance, such fibers could be PBO Zylon fiber, a strong yet lightweight fiber, available from Toyobo. Alternatively, fibers  152  may be made of any other material having comparable weight and strength. Jacket  154  is made of Rilsan. Alternatively, jacket  154  may be made of any other material having comparable weight and strength. Each nipple access hole  124  allows access to nipple head  198  so that it can be turned to facilitate the threading of nipple  190  onto tube  170 . For instance, a hexagonal head nut-driver may be positioned over nipple  190  and rotated to tighten spoke  150  in place. 
         [0035]      FIG. 4  shows a cross-sectional detail view of the inside of a spoke  150 , showing the fibers  152 , outer diameter  158 , and inner diameter  156  of jacket  154 . Fibers  152  are gathered in forty-four (44) bundles  410  of nine hundred ninety-six (996) fibers  152  in each bundle, for a total of 43,824 fibers  152  in spoke  150 . This great number of fibers  152  is one factor contributing to the great strength of spoke  150 , while minimizing the weight of spoke  150 . Spoke  150  has a breaking strength of 3,600 pounds. Alternatively, the number of bundles  410  may be greater or less than 44; the number of filaments in each bundle  410  may be greater or less than 996; and the breaking strength of spoke  150  may be greater or less than 3,600 pounds. 
         [0036]    Referring to  FIG. 5 , a cross-sectional view of the first preferred embodiment of the wheel with flexible spokes of the present invention showing cross-sectional portions of the rim and hub is shown. As can be appreciated from  FIG. 5 , the width of rim  110  is just slightly wider than the width of nipple  190 . As a result, it is necessary that nipple  190  be aligned so that the spoke  150  extends radically inward from rim  110 . Because of this positioning, it is important that spoke  150  be flexible as it leaves nipple  190  so as to accommodate angle  250  without any decrease in strength and durability. Due to the number of fibers  152  contained within spoke  150 , there is no noticeable decrease in strength despite the off-axis tension. 
         [0037]    When tension is applied to spoke  150 , collar  196  strikes the inside surface of rim  110  and maintains the nipple  190 , and corresponding sleeve, in its perpendicular arrangement. 
         [0038]    Referring to  FIG. 6 , an alternative embodiment of the flexible spoke is shown and generally designated  700 . Spoke  700  consists of a tube  170  having threads  174 , an anchor  180 , and a jacket  702 . When mounted into rim  110 , threads  174  engage with threads  194  (not shown, see  FIG. 5 ) in nipple  190 . In this alternative embodiment, jacket  702  is formed in the shape of a teardrop (see  FIG. 8 ). As is known in the industry, teardrop shapes are efficient due to the reduced amount of drag produced by the flow of air over the shape. In this embodiment, jacket  702  consists of a leading edge  714  and a trailing edge  716 . When spoke  700  in installed in wheel  100 , spoke  700  is oriented such that leading edge  714  points in direction  102 , which is the direction of rotation of wheel  100 . It is to be appreciated that trailing edge  716  points in the direction opposite direction  102 . 
         [0039]    In this embodiment, the teardrop shape creates less drag than a typical round spoke due the reduced drag created by the teardrop shaped jacket  702 . Less drag is due to the reduced wake created when spoke  700  rotates through aft as compared to a typical round spoke. A typical round spoke has only 50% of the drag of a flat plate traveling at the same rate through the air. However, a properly dimensioned teardrop shape has 5% or less of the drag of a flat plate traveling at the same rate through the air. Even an improperly dimensioned teardrop shape has approximately 5%-20% of the drag of a flat plate traveling at the same rate through the air. 
         [0040]    During typical bicycle racing, riders can achieve speeds of 40 mph. For a typical wheel, this means that the outer end of spoke  700  is also traveling at approximately 40 mph thereby creating increased drag as measured when moving away from the hub of the wheel. Assuming a racing bike wheel has a diameter of 22 inches, 40 mph roughly translates into the rim portion of the wheel rotating at 704 inches per second, meaning that the outer portion of a spoke is also moving through the air at approximately 704 inches per second. In contrast, the portion of the spoke measured at 6 inches from the center of the wheel&#39;s hub is traveling at 333 inches per second. When racing, this increased drag caused by round spokes moving at the above mentioned speeds reduces the bicycle&#39;s speed thereby requiring the expending of more energy to maintain the desired speed of 40 mph. As the number of spokes is increased, the amount of drag created by the spokes also increases. 
         [0041]    To minimize the amount of drag created by the round spokes moving through the air, an aerodynamic jacket is applied to the spoke. In  FIG. 6 , a teardrop jacket  702  is shown applied to a spoke  700 . When jacket  702  is properly applied to the spoke  700  such that leading edge  714  travels in direction  102 , spoke  700  will have greatly reduced drag effects, up to 95% less than round spokes without an aerodynamic cover. The reduced drag results in a reduced amount of energy required to maintain any given speed. Alternatively, a higher speed may be achieved when applying the same amount of energy to a wheel having typical round spokes. This reduced drag effect will be a substantial benefit to a person racing on a bike with aerodynamic spokes as compared to a person racing without aerodynamic spokes since, in part, the difference between 1 st  and 10 th  place in a bicycle race can be one (1) second or less. Over the course of a bicycle race, the reduced drag can result in decreasing race times by several seconds. 
         [0042]    Moving on to  FIG. 7 , a cross-section of the spoke  700  taken through line  7 - 7  of  FIG. 6  is shown. Fibers  152  are shown with a jacket in the shape of a teardrop formed around fibers  152 , having a leading edge  714  and a trailing edge  716 . Fibers  152  are located in the leading half of the spoke  700  as defined by line  704 . Fibers  152  are also located in the centerline of spoke  700  as defined by line  706 . It is to be appreciated that fibers  152  may be located at any point along line  706  from intersection  708  to leading edge  714 , with fibers  152  typically located around the mid-point of the line between intersection  708  and leading edge  714 . 
         [0043]      FIGS. 6 and 9  show alternative cross-sections of an aerodynamic spoke.  FIG. 8  shows a cross section view of an aerodynamic spoke formed in an oblong shape. In this embodiment, the spoke must be oriented such that the leading edge  714  and trailing edge  716  are in-line with direction  102 .  FIG. 9  is another alternative embodiment of the present invention.  FIG. 9  shows a cross section view of an aerodynamic spoke formed with a pointed leading edge  714  and trailing edge  716 . As with the embodiment in  FIG. 8 , aerodynamic spoke  730  must be oriented such that leading edge  714  and trailing edge  716  are in-line with direction  102 . Similar to the tear drop shape discussed in relation to  FIG. 7 , the oblong shape and the pointed shape spokes will also work to reduce drag created by the spoke as it rotates in the air. 
         [0044]    Now referring to  FIG. 10 , a mold for manufacturing the aerodynamic spoke of the present invention is shown and generally designated  800 . Mold  800  consists of upper block  802  and lower block  804 . Upper block  802  has an upper channel  806  formed in the shape of the desired jacket, such as the teardrop shape of  FIG. 7 . Lower block  804  has a lower channel  808  corresponding to upper channel  806 . To manufacture an aerodynamic spoke of the present invention, Fibers  152  are gathered into the desired number of bundles and cut to the desired length to form bundle  410 . Bundle  410  is then placed in lower channel  808  of lower block  804  such that the ends of bundle  410  extend beyond the edges of lower block  804 . Upper block  802  is then secured to lower block  804  in direction  810  such that bundle  410  is located in the space formed between upper and lower channels  806  and  808 . The desired material used to form the jacket is then injected into the channel causing the material to form in the shape of the space created by upper and lower channels  806  and  808 . After the newly formed aerodynamic spoke has solidified in mold  800 , upper block  802  and lower block  804  are separated thereby releasing the spoke from the mold  800 . 
         [0045]    Due to the shape and size of an aerodynamic spoke of the present invention  150  as compared to a traditional spoke, jacket  702  may not pass through flange hole  140  thereby preventing the assembly of the spoke into wheel  100 . To overcome this limitation, anchor  180  may be designed such that inner end  162  is formed with a tube similar to tube  170  having threads on the outside of the tube. To assemble wheel  100 , the near end  162  of spoke with aerodynamic jacket  150  is inserted through flange hole  140  then secured with a nipple, similar to nipple  190 . Far end  164  is then inserted into nipple  190  and tightened until the desired tension is achieved. 
         [0046]    Referring now to  FIG. 11 , a perspective view of an alternative heated mold is shown and generally referred to as  900 . Mold  900  consists of upper block  902  having upper channel  906  and heater  910 , lower block  904  having lower channel  908  and heater  911  (shown in dashed lines), spoke blank  912  having a first end  914  and a second end  916  and covered in a jacket  918 . As shown in  FIG. 11 , upper and lower channels  906  and  908  transition from a first shape (Teardrop, See  FIG. 7 ) to a second shape (Oblong, See  FIG. 8 ). In practice, as will be discussed further below, heated mold  900  will result in a spoke where jacket  918  has a teardrop cross-section (See  FIG. 7 ) along one portion of the spoke, which then transitions into an oblong cross-section along the remaining portion (See  FIG. 8 ). It is to be appreciated by someone skilled in the art that spoke  912  may be formed with three or more cross-sections along the length of spoke  912  to create a specific drag profile along the length of spoke  912 . 
         [0047]    New Referring to  FIG. 12 , heated mold  900  is shown in the closed position by bring upper block  902  and lower block  904  together with spoke blank  912  located between upper and lower block  902  and  904  in upper and lower channels  906  and  908 . When mold  900  is in the closed position, heaters  910  and  911  are energized to heat blank  912  such that jacket  918  forms to the shape of upper and lower channels  906  and  908 . After spoke  912  has formed to upper and lower channels  906  and  908 , heaters  910  and  911  are de-energized to allow mold  900  and spoke blank  912  to cool to ambient temperature. 
         [0048]    In  FIG. 13 , after mold  900  and spoke blank  912  have cooled to ambient temperature, upper block  902  and lower block  904  are separated allowing spoke  912  to be removed from mold  900 . As can be seen in  FIG. 13 , spoke  912  now has two distinct cross-sections. The first cross-section, as taken through line  7 - 7 , at first end  914  is a tear-drop shape as seen in  FIG. 7 . Moving toward second end  916 , spoke  912  transitions from the tear-drop shape of  FIG. 7  to an oblong shape, as taken through line  8 - 8 , as shown in FIG.  8 . It is to be appreciated by someone skilled in the art that spoke  912  may be a combination of two or more shapes as needed to minimize wind resistance. For example, spoke  912  may have a teardrop shape (See  FIG. 7 ) at first end  914  and an aerodynamic shape having pointed leading and trailing edges (See  FIG. 9 ) at second end  916 . As a further example, spoke  912  may be formed with a teardrop shape that transitions into an oblong shape that in turn transitions into a round shape. 
         [0049]    It is to be appreciated by someone skilled in the art that the aerodynamic spoke described in reference to  FIGS. 11-13  may be created by injecting the jacket material into mold  900 , as described in conjunction with  FIG. 10 . To form a spoke, a fiber bundle is inserted into the channel formed by upper and lower channels  906  and  908  when upper block  902  is closed against lower block  904 . Next, the jacket material is injected into the formed channel containing the fiber bundle. In certain embodiments, mold  900  may require the use of one of more heaters to aid in the manufacturing process. In other embodiments, the injected jacket material may be injected when mold  900  is at ambient temperature. After the spoke is formed, upper block  902  and lower block  904  are separated and the aerodynamic spoke is removed from mold  900 . 
         [0050]    While the wheel with flexible spokes of the present invention as herein shown and disclosed in detail is fully capable of obtaining the objects and providing the advantages herein before stated, it is to be understood that it is merely illustrative of preferred and alternative embodiments of the invention and that no limitations are intended to the details of construction or design herein shown other than as described in the appended claims.