TWI840187B - Manufacturing method of carbon fiber spoke - Google Patents

Abstract

The present invention provides a manufacturing method of carbon fiber spoke, which includes sequentially steps of impregnating, shaping the main body, setting joints and expanding the diameter, wherein the expanding diameter step is to press the two ends of the long rod-shaped main body in a plastic state along the axial direction of the main body, forcing the wrapping body that constitutes the main body to produce axial collapse and radial expanded material flow to form two expanding diameter part. The flowing wrapping body induces several carbon fiber filaments forming the main body to be curled and deformed respectively to form two curled sections. Each curled sections extends to both ends of each carbon fiber filament, and each curled section is located at each expanding diameter part, and the length of each curled section is respectively greater than the axial length of each expanding diameter part, so as to strengthen each expanding diameter part.

Description

Method for manufacturing carbon fiber spokes

The present invention relates to a spoke of a rim, and more particularly to an innovative technical disclosure of a method for manufacturing a carbon fiber spoke.

A wheel rim for arranging a tire comprises a circular frame, a wheel hub and a plurality of long rod-shaped spokes, wherein the circular frame is provided with a tire ring, the wheel hub is located at the circular center of the circular frame, and each of the spokes is provided with a spoke joint at both ends, and each of the spoke joints located at both ends of the spoke is used to connect the circular frame and the wheel hub, and each of the spokes provides support for the circular frame and the wheel hub, so that the circular frame and the wheel hub are relatively positioned.

The spokes can be made of metal or carbon fiber composite materials. Compared with the metal materials commonly used to make the spokes, the carbon fiber composite materials have higher strength and lighter weight, and excellent properties such as water resistance and corrosion resistance. The spokes made of carbon fiber composite materials have been widely used in high-quality bicycle rims.

However, the spokes made of carbon fiber composite materials still have some problems and bottlenecks in the current practical application experience and need to be further broken through. For example, because carbon fiber composite materials are quite hard and brittle, the final product shape must be accurately planned in advance at the initial production mold stage. After the molding and curing, it is almost impossible to change the shape. Therefore, the spokes made of carbon fiber composite materials are usually required to use some other additional components such as the positioning and anti-detachment of the wheel rim. Retaining rings, pins or hoops, etc., and secondary processing and auxiliary mold processes, or partial wrapping and curing and reprocessing and material removal, etc., are used to facilitate the formation of a shape with an anti-slip limit function at the end of the web. However, due to the existence of additional components and subsequent processing, the industry's process is still too complicated and the material cost is difficult to simplify, which leads to the difficulty of further reducing the manufacturing cost, thereby not meeting the best industrial economic benefits.

The main purpose of the present invention is to provide a method for manufacturing a carbon fiber spoke. The technical problem it aims to solve is to explore and innovate a new method for manufacturing the spoke that is more ideal and practical.

Based on the above purpose, the technical feature of the present invention to solve the problem is mainly that the manufacturing method of the carbon fiber web includes the following steps performed in sequence:

Impregnation: several long carbon fiber filaments are gathered into a bundle, and each of the carbon fiber filaments is guided to pass through a resin in a flowable state, so that the resin forms a coating body to wrap each of the carbon fiber filaments gathered into a bundle, thereby obtaining a long rod-shaped main body, and each of the carbon fiber filaments is respectively wrapped by the coating body;

Main body shaping: the main body is guided into a shaping mold, the temperature of the main body is treated to shape the main body, and the main body is cut into sections according to the preset length;

Sleeve joints: The main body is axially sleeved with two pre-prepared joints for connecting the annular frame and the wheel hub, respectively, and each of the joints is a tubular structure; and

Diameter expansion: The two ends of the main body are placed in a diameter expansion mold respectively, and the two ends of the main body in a plastic state are pressed along the axial direction of the main body, forcing the coating to produce axial contraction and radial expansion of the material flow to form two diameter expansion parts. The flowing coating induces each carbon fiber filament to curl and deform to form two curling sections, and each curling section extends At the two ends of each carbon fiber filament, each curled section is located at each expanded diameter portion, and the length of each curled section is greater than the axial length of each expanded diameter portion. The main body forms a long rod section between each expanded diameter portion, and the outer diameter of each expanded diameter portion is greater than the outer diameter of the long rod section. The coating is then solidified and shaped to obtain a carbon fiber strip.

The main effects and advantages of the present invention are that the main body constituting the carbon fiber web integrally forms the respective expanded diameter portions, and the respective carbon fiber filaments form the curled sections inside the respective expanded diameter portions, so that the strength of the expanded diameter portions to withstand the applied force can be improved, and when the respective joints form a reverse applied force on the main body along the axial direction, the respective expanded diameter portions of the respective joints and their rings are not easy to come off, and no other additional components are required, and no secondary processing and auxiliary mold processes are required, and the structure can be integrally formed to form an assembly anti-detachment function, thereby achieving practical progress and better industrial economic benefits in greatly reducing the material, manufacturing, and processing costs of the carbon fiber web.

Please refer to the drawings, which are preferred embodiments of the method for manufacturing the carbon fiber web of the present invention. However, these embodiments are for illustrative purposes only and are not limited to this structure in patent applications.

As shown in FIGS. 1 to 7 , the method for manufacturing the carbon fiber web comprises the following steps performed in sequence:

Impregnation: A plurality of long carbon fiber filaments 11 are gathered into a bundle, and each of the carbon fiber filaments 11 is guided through a resin in a flowable state, so that the resin forms a coating 12 that wraps each of the carbon fiber filaments 11 gathered into a bundle, thereby obtaining a long rod-shaped main body 10, and each of the carbon fiber filaments 11 is respectively wrapped by the coating 12.

Main body shaping: The main body 10 is guided into a shaping mold (not shown), the main body 10 is subjected to temperature treatment to shape the main body 10, and the main body 10 is cut into sections according to a preset length.

Sleeve joints: The main body 10 is axially sleeved with two pre-prepared joints 20 respectively used to connect the annular frame (not shown) and the wheel hub (not shown), and each of the joints 20 is a tubular structure.

Diameter expansion: The two ends of the main body 10 are placed in a diameter expansion mold respectively, and the two ends of the main body 10 in a plastic state are pressed along the axial direction of the main body 10, forcing the wrapping body 12 to produce axial contraction and radial expansion of the material flow to form two diameter expansion parts 13. The flowing wrapping body 12 causes each carbon fiber filament 11 to curl and deform to form two curling sections 14. Each curling section 14 extends to each At both ends of the carbon fiber filament 11, each curling section 14 is located at each expanded diameter portion 13, and the length of each curling section 14 is greater than the axial length of each expanded diameter portion 13. The main body 10 forms a long rod section 15 between each expanded diameter portion 13, and the outer diameter of each expanded diameter portion 13 is greater than the outer diameter of the long rod section 15. Then, the coating body 12 is solidified and shaped, thereby obtaining a carbon fiber strip.

When each of the connectors 20 is made of heat-resistant material, each of the connectors 20 can be used as the expansion mold, and two punches 30 can be used to press the two ends of the main body 10 along the axial direction of the main body 10, thereby forming each of the expansion parts 13.

The two ends of each joint 20 along the axial direction are respectively a first end 21 and a second end 22, and each second end 22 of each joint 20 is respectively located between each first end 21, and each joint 20 is respectively formed with a first set of holes 23 and a second set of holes 24 along the axial direction, the first set of holes 23 extends to the first end 21, the second set of holes 24 extends to the second end 22, and the first set of holes 23 and the second set of holes 24 are connected along the axial direction of the joint 20 The inner diameter of the first set of holes 23 is adapted to the outer diameter of the expansion portion 13, the inner diameter of the second set of holes 24 is adapted to the outer diameter of the long rod section 15, and each of the joints 20 surrounds the first set of holes 23 and the second set of holes 24 to form a seamless hole wall, so that each of the joints 20 respectively forms a portion of each of the second set of holes 24 surrounding the radial periphery of the long rod section 15, and the covering body 12 cooperates with each of the first set of holes 23 of each of the joints 20 to flow to form each of the expansion portions 13.

In the expansion step, when the two ends of the long rod-shaped main body 10 are respectively placed into the joints 20 through the second ends 22, the two ends of the main body 10 are preferably not protruded from the first ends 21, and the two ends of the main body 10 are respectively aligned with the first ends 21 along the radial direction.

In the process of the material flow of the coating 12 which generates axial contraction and radial expansion to form each of the expansion portions 13, each of the carbon fiber filaments 11 is respectively drawn by the flow of the coating 12 and curled to form each of the curled sections 14. Each of the curled sections 14 is respectively located inside each of the expansion portions 13. The material flow of the coating 12 and the expansion portions 13 are The length of each curled section 14 will not be reduced. The length of each curled section 14 is greater than the axial length of each expanded portion 13. The density of the carbon fiber filament 11 in each expanded portion 13 is significantly higher than that of the long rod section 15. The proportion of the carbon fiber filament 11 in the overall structure of each expanded portion 13 is higher than that of the long rod section 15.

In the carbon fiber web manufactured by executing the above-mentioned preferred embodiment, each of the expansion portions 13 and each of the joints 20 forms a one-way stop with each other, each of the expansion portions 13 cannot be separated from each of the joints 20 through the second end 22, and each of the joints 20 cannot be separated from the main body 10 in a direction away from the long rod section 15. Each of the curling sections 14 enables each of the expansion portions 13 to be more capable of bearing a force than the long rod section 15, and the strength of each of the expansion portions 13 is improved. The degree of the joint 20 is improved, so that when each joint 20 forms a reverse force on the main body 10 along the axial direction, each joint 20 and each expanded diameter portion 13 of the ring are not easy to be separated, and there is no need to use other additional components, nor is there any need for secondary processing and auxiliary processes of molds. The structure can be used to form an assembly anti-separation function, thereby achieving practical progress and better industrial economic benefits in greatly reducing the material, manufacturing and processing costs of the carbon fiber spokes.

The expansion step can be selected to further force the wrapping body 12 to expand radially to form two connecting sections 16, each connecting section 16 is respectively connected to each of the expansion sections 13 and the long rod section 15, the outer diameter of each connecting section 16 decreases from each of the expansion sections 13 connected to the long rod section 15, and the outer diameters of the two ends of each connecting section 16 are respectively matched with the outer diameters of each of the expansion sections 13 and the long rod section 15 connected to each other. In this example, the radial periphery of each of the connecting sections 16 is respectively selected to be a cone, and the shape of the radial periphery of each of the connecting sections 16 can also be selected to be replaced by other types that gradually expand from one end to the other end.

In cooperation with the formation of each of the connecting sections 16, when each of the connectors 20 is selected as the expansion die, each of the connectors 20 forms the first set of holes 23, a connecting hole 25 and the second set of holes 24 in sequence along the axial direction. The two ends of the connecting hole 25 are connected to the first set of holes 23 and the second set of holes 24 respectively. The inner diameter of each of the connecting holes 25 decreases from one end connected to the first set of holes 23 to one end connected to the second set of holes 24, and the inner diameters of the two ends of each of the connecting holes 25 are respectively matched with the inner diameters of the connected first set of holes 23 and the second set of holes 24. Each of the connectors 20 surrounds the radial periphery of each of the connecting sections 16 respectively, and the hole wall of each of the connecting holes 25 formed by each of the connectors 20 abuts against each of the connecting sections 16 along the axial direction.

The resin constituting the wrapping body 12 can be selected from any one of the following thermoplastic resin materials or any mixture thereof: nylon, polyethylene, polypropylene, polyvinyl chloride, acrylonitrile-butadiene-styrene, polystyrene, polyoxymethylene, polycarbonate, polyurethane, polytetrafluoroethylene, polyethylene terephthalate, polyphenylene sulfide or polyetheretherketone.

When the resin is a thermoplastic resin material, the diameter expansion step is to place the two ends of the main body 10 into the diameter expansion molds respectively, and heat and pressurize the main body 10 to form the diameter expansion parts 13.

The resin constituting the wrapping body 12 may be a thermosetting resin material. At this time, the expansion step is to place the two ends of the uncured main body 10 into the expansion molds respectively, extrude the main body 10 to form the expansion parts 13, and then heat the main body 10 to the curing temperature so that the main body 10 is cured and shaped into the carbon fiber strips. The curing temperature may be 220°C.

6: A partial enlargement of the 6-6 section is shown in Figure 6 7: A partial enlargement of the 7-7 section is shown in Figure 7 10: Main body 11: Carbon fiber filament 12: Wrapping body 13: Expanded diameter section 14: Curled section 15: Long rod section 16: Joint section 20: Joint 21: First end 22: Second end 23: First set of holes 24: Second set of holes 25: Connecting hole 30: Punch head

FIG. 1 is a flow chart of a preferred embodiment of the present invention. FIG. 2 is a schematic diagram of the expansion step and the expansion forming state of the preferred embodiment of the present invention. FIG. 3 is a schematic diagram of the expansion step and the expansion forming state of the preferred embodiment of the present invention. FIG. 4 is a three-dimensional diagram of the carbon fiber strip obtained by executing the preferred embodiment of the present invention. FIG. 5 is an axial cross-sectional view of the carbon fiber strip obtained by executing the preferred embodiment of the present invention. FIG. 6 is a partial enlarged view of the 6-6 section of FIG. 5, showing the cross section of the coating and the carbon fiber filament along the direction perpendicular to the axial line. Figure 7 is a partial enlarged view of section 7-7 of Figure 5, showing the cross section of the coating and carbon fiber along the direction perpendicular to the axial line.

Claims (8)

A method for manufacturing a carbon fiber spoke comprises the following steps performed in sequence: Impregnation: taking a plurality of long carbon fiber filaments and gathering them into a bundle, and guiding each of the carbon fiber filaments to pass through a resin in a flowable state, so that the resin forms a coating body to wrap each of the carbon fiber filaments gathered into a bundle, thereby obtaining a long rod-shaped main body, and each of the carbon fiber filaments is respectively wrapped by the coating body; Main body shaping: guiding the main body into a shaping mold, performing temperature treatment on the main body, shaping the main body, and cutting the main body into sections according to a preset length; Sleeve joint: axially sleeve the main body with two pre-prepared joints for connecting a ring frame and a wheel hub, each of which is a tubular structure; and Diameter expansion: The two ends of the main body are placed in a diameter expansion mold respectively, and the two ends of the main body in a plastic state are pressed along the axial direction of the main body, forcing the coating to produce axial contraction and radial expansion of the material flow to form two diameter expansion parts. The flowing coating induces each carbon fiber filament to curl and deform to form two curling sections, and each curling section extends At the two ends of each carbon fiber filament, each curling section is located at each expanded diameter portion, and the length of each curling section is greater than the axial length of each expanded diameter portion. The main body forms a long rod section between each expanded diameter portion, and the outer diameter of each expanded diameter portion is greater than the outer diameter of the long rod section. Then, the coating body is solidified and shaped, thereby obtaining a carbon fiber strip. A method for manufacturing a carbon fiber spoke as described in claim 1, wherein each of the joints is made of a heat-resistant material, and each of the joints is used as the expansion mold. The two axial ends of each of the joints are respectively a first end and a second end, and each of the second ends of each of the joints is respectively located between each of the first ends. Each of the joints forms a first set of holes and a second set of holes along the axial direction, the first set of holes extends to the first end, the second set of holes extends to the second end, and the first set of holes and the second set of holes are connected along the axial direction of the joint, the inner diameter of the first set of holes is adapted to the outer diameter of the expansion portion, the inner diameter of the second set of holes is adapted to the outer diameter of the long rod section, and each of the joints surrounds the first set of holes and the second set of holes to form a seamless hole wall. A method for manufacturing a carbon fiber web as described in claim 1, wherein the expansion step further forces the coating body to expand radially to form two connecting sections, each of which is respectively connected to the expansion portion and the long rod section, and the outer diameter of each connecting section decreases from the connected expansion portion toward the long rod section, and the outer diameters of both ends of each connecting section are respectively matched with the outer diameters of the connected expansion portion and the long rod section. A method for manufacturing a carbon fiber web as described in claim 3, wherein each of the joints is made of a heat-resistant material, each of the joints is used as the expansion mold, each of the two ends of the joint along the axial direction is a first end and a second end, and each of the second ends of the joints is located between each of the first ends, each of the joints is formed with a first set of holes, a through hole and a second set of holes in sequence along the axial direction, the first set of holes extends to the first end, the second set of holes extends to the second end, and the first set of holes extends to the second end. The hole extends to the second end, and the two ends of the connecting hole are respectively connected to the first set of holes and the second set of holes, the inner diameter of the first set of holes is adapted to the outer diameter of the expanded portion, and the inner diameter of the second set of holes is adapted to the outer diameter of the long rod section, and the inner diameter of each connecting hole decreases from one end connected to the first set of holes toward one end connected to the second set of holes, and the inner diameters of the two ends of each connecting hole are respectively matched with the inner diameters of the first set of holes and the second set of holes connected thereto. A method for manufacturing a carbon fiber web as described in any one of claims 1 to 4, wherein the resin is selected from any one of the following thermoplastic resin materials or any mixture thereof: nylon, polyethylene, polypropylene, polyvinyl chloride, acrylonitrile-butadiene-styrene, polystyrene, polyoxymethylene, polycarbonate, polyurethane, polytetrafluoroethylene, polyethylene terephthalate, polyphenylene sulfide or polyetheretherketone. A method for manufacturing a carbon fiber web as described in claim 5, wherein the diameter expansion step is to place the two ends of the main body into each of the diameter expansion molds, and heat and pressurize the main body to form each of the diameter expansion parts. A method for manufacturing a carbon fiber web as described in any one of claims 1 to 4, wherein the resin is a thermosetting resin material. A method for manufacturing a carbon fiber web as described in claim 7, wherein the expansion step is to place the two ends of the uncured main body into the expansion molds respectively, extrude the main body to form the expansion portions, and then heat the main body to a curing temperature so that the main body is cured and shaped into the carbon fiber web.

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