A method for manufacturing carbon fiber spokes and carbon fiber spokes

Abstract

This invention discloses a method for manufacturing carbon fiber spokes and the carbon fiber spokes themselves. The manufacturing method includes the following steps: 1) rolling carbon sand sheets into rods and filling at least both ends with foaming agent; 2) fitting one end of the rod into a nut that can be connected to a bicycle rim, and fitting the other end of the rod into a headstock that can be connected to a hub, wherein the inner wall surfaces of the nut and the headstock are respectively provided with concave and convex structures; 3) curing the rod to form a carbon fiber spoke rod, wherein the outer wall surfaces at both ends of the carbon fiber spoke rod are respectively engaged with the inner wall surfaces of the nut and the headstock. This invention, by rolling carbon sand sheets into rods and filling at least both ends with foaming agent, and then fixing them to the nut and headstock through curing, while simultaneously forming an engaged state, not only simplifies the process but also greatly improves the tensile strength of the carbon fiber spokes.

Description

Technical Field

[0001] This invention relates to a vehicle spoke, and more particularly to a method for manufacturing a carbon fiber spoke and the carbon fiber spoke itself. Background Technology

[0002] Bicycle spokes are typically used to connect the rim and hub. Traditional bicycle spokes are made of stainless steel, which is heavy, costly, and has low production efficiency. To address this issue, carbon fiber spokes have emerged, consisting of a carbon fiber spoke bar and a threaded cap and a bead connecting the two ends of the spoke bar. The threaded cap and bead are usually bonded to the carbon fiber spoke. During use, the hub and rim exert tensile forces on the threaded cap and bead, making them prone to being pulled away from the carbon fiber spoke bar. Summary of the Invention

[0003] This invention addresses the technical problems existing in the prior art by providing a method for manufacturing carbon fiber spokes with high tensile strength and simple process, as well as the carbon fiber spokes themselves.

[0004] The technical solution adopted by this invention to solve its technical problem is: a method for manufacturing carbon fiber spokes, comprising the following steps:

[0005] 1) Roll the carbon sand sheet into a rod and fill it with foaming agent at least at both ends;

[0006] 2) Insert one end of the rod into the nut that can be connected to the rim, and insert the other end of the rod into the head that can be connected to the hub. The inner wall of the nut and the inner wall of the head are respectively provided with concave and convex structures.

[0007] 3) The rod is cured to form a carbon fiber spoke rod, and the outer wall surfaces at both ends of the carbon fiber spoke rod are engaged with the inner wall surfaces of the tooth cap and the cap head, respectively.

[0008] Furthermore, step 3) includes the following steps:

[0009] 31) Place the pre-impregnated resin rod and its toothed cap and cap head into the molding groove of the molding die;

[0010] 32) Place the molding die into the high-temperature curing equipment to cure the rod at high temperature;

[0011] 33) After curing is complete, remove the molding mold, and take out the bar and its tooth cap and cap head to form the finished carbon fiber spoke.

[0012] Furthermore, there are multiple forming grooves, which are arranged in at least one row, and each forming groove corresponds to a bar.

[0013] Furthermore, the concave-convex structure is wavy and spiral-shaped, or the concave-convex structure includes a plurality of annular grooves spaced apart along the axial direction.

[0014] Furthermore, the inner diameter of the dental cap gradually decreases from its outer end to its inner end; the inner diameter of the cap head gradually decreases from its outer end to its inner end.

[0015] Furthermore, the carbon yarn sheet is formed into a bar using a twisting and rolling process.

[0016] Furthermore, the foaming agent is a black foaming agent.

[0017] The present invention also provides a carbon fiber spoke, comprising a carbon fiber spoke rod, a nut that can be fitted to connect to a rim, and a head that can be fitted to connect to a hub. The inner wall surface of the nut and the inner wall surface of the head are respectively provided with concave and convex structures. One end of the carbon fiber spoke rod is inserted into the nut, and the outer wall surface of that end of the carbon fiber spoke rod engages with the inner wall surface of the nut. The other end of the carbon fiber spoke rod is inserted into the head, and the outer wall surface of that end of the carbon fiber spoke rod engages with the inner wall surface of the head.

[0018] Furthermore, the concave-convex structure is wavy and spiral-shaped, or the concave-convex structure includes a plurality of annular grooves spaced apart along the axial direction.

[0019] Furthermore, the carbon fiber spoke rod is formed by rolling carbon sand sheets into a rod and then curing it; the carbon fiber spoke rod is thicker in the middle and thinner at both ends.

[0020] Furthermore, the inner diameter of the dental cap gradually decreases from its outer end to its inner end; the inner diameter of the cap head gradually decreases from its outer end to its inner end.

[0021] Compared with the prior art, the present invention has the following beneficial effects:

[0022] 1. The present invention rolls carbon sand sheets into rods and fills at least both ends with foaming agent. The rods are then fixed to the inner wall surface by curing and forming a meshing state with tooth caps and cap heads that are concave and convex. This not only simplifies the process but also greatly improves the tensile strength of carbon fiber spokes.

[0023] 2. The curing process of the rod is carried out by the molding mold, which can avoid the rod bending and the process is simple.

[0024] 3. The concave-convex structure is wavy and spiral, or the concave-convex structure includes multiple annular grooves spaced apart along the axial direction, which makes the engagement of the carbon fiber spoke bar with the tooth cap and the cap head very firm, thereby effectively improving the tensile strength of the carbon fiber spoke.

[0025] 4. The inner diameter of the tooth cap gradually decreases from its outer end to its inner end, and the inner diameter of the cap head gradually decreases from its outer end to its inner end, so that the carbon fiber spokes of the present invention become increasingly tight under tensile force, thereby further improving the tensile strength of the present invention. The present invention will be further described in detail below with reference to the accompanying drawings and embodiments; however, the method for manufacturing carbon fiber spokes and the carbon fiber spokes of the present invention are not limited to the embodiments. Attached Figure Description

[0026] Figure 1 This is a cross-sectional view of the carbon fiber spokes of the present invention;

[0027] Figure 2 This is an enlarged schematic diagram of one end of the carbon fiber spoke of the present invention;

[0028] Figure 3 This is an enlarged schematic diagram of the other end of the carbon fiber spoke of the present invention;

[0029] Figure 4 This is a schematic diagram showing the fit between the molding die and the carbon fiber spokes of the present invention. Detailed Implementation

[0030] For an example, please refer to [link / reference]. Figures 1-4 As shown, a method for manufacturing carbon fiber spokes according to the present invention includes the following steps:

[0031] 1) Roll the carbon sand sheet at 0 degrees into a rod and fill the inside of both ends with foaming agent;

[0032] 2) Insert one end of the bar into the nut 3 that can be connected to the rim, and insert the other end of the bar into the head 2 that can be connected to the hub. The inner wall of the nut 3 and the inner wall of the head 2 are respectively provided with concave and convex structures 31 / 21.

[0033] 3) The rod is cured to form a carbon fiber spoke rod 1, and the outer wall surfaces at both ends of the carbon fiber spoke rod 1 are engaged with the inner wall surfaces of the tooth cap 3 and the cap head 2, respectively.

[0034] In this embodiment, step 3) specifically includes the following steps:

[0035] 31) Place the pre-impregnated resin rod and its toothed cap 3 and cap head 2 into the molding groove set in the molding mold 4;

[0036] 32) Place the molding mold 4 into the high-temperature curing equipment to cure the rod at high temperature;

[0037] 33) After curing is complete, remove the molding mold 4, and take out the bar and its tooth cap 3 and cap head 2 to form the finished carbon fiber spoke.

[0038] In this embodiment, there are multiple forming grooves arranged in a row, and each forming groove corresponds to a bar. The size and shape of the forming grooves are approximately adapted to the size and shape of the carbon fiber spokes, and a 0.05mm gap is reserved between the groove wall and the tooth cap 3 and the cap head 2, respectively.

[0039] In this embodiment, the concave-convex structure 31 / 21 is wavy and spiral-shaped, but it is not limited to this. In other embodiments, the concave-convex structure includes multiple annular grooves spaced apart along the axial direction. The axial direction refers to the axial direction of the cap or head. In this embodiment, the inner diameter of the cap 3 gradually decreases from its outer end to its inner end, and the inner diameter of the head 2 gradually decreases from its outer end to its inner end. Therefore, the inner cavities of the cap 3 and the head 2 are approximately conical, and the difference in inner diameter between their inner and outer ends is approximately 1 mm. The outer end of the cap 3 and the outer end of the head 2 refer to the ends away from the middle of the carbon fiber spoke rod 1, and the inner end of the cap 3 and the inner end of the head 2 refer to the ends closer to the middle of the carbon fiber spoke rod 1.

[0040] In this embodiment, the carbon yarn sheet is formed into a rod using a twisting and rolling process. The foaming agent is a black foaming agent.

[0041] This invention discloses a method for manufacturing carbon fiber spokes. A foaming agent is inserted into both ends of a rod. During curing, the foaming agent expands upon heating, enlarging the sidewalls around the ends of the rod and causing them to tightly adhere to the inner walls of the tooth cap 3 and the head cap 2. Since the inner walls of the tooth cap 3 and the head cap 2 are respectively provided with wavy, spiral-shaped concave-convex structures 31 / 21, the sidewalls around the ends of the rod form a matching wavy spiral shape. This results in the outer walls at both ends of the cured carbon fiber spoke rod 1 forming an internal-external meshing state (i.e., tooth-like engagement) with the inner walls of the tooth cap 3 and the head cap 2, respectively. Simultaneously, the inner diameter of the tooth cap 3 gradually decreases from its outer end to its inner end, and the inner diameter of the head cap 2 also gradually decreases from its outer end to its inner end. Under tensile force, the carbon fiber spokes become increasingly tight, thereby greatly improving the tensile strength of the carbon fiber spokes. This invention, using a carbon fiber spoke rod 1, significantly reduces the weight of bicycle spokes.

[0042] Please see Figures 1-4 As shown, the present invention provides a carbon fiber spoke, including a carbon fiber spoke rod 1, a nut 3 that can be connected to a rim, and a head 2 that can be connected to a hub. The inner wall surface of the nut 3 and the inner wall surface of the head 2 are respectively provided with concave and convex structures 31 / 21. One end of the carbon fiber spoke rod 1 is inserted into the nut 3, and the outer wall surface of that end of the carbon fiber spoke rod 1 engages with the inner wall surface of the nut 3. The other end of the carbon fiber spoke rod 1 is inserted into the head 2, and the outer wall surface of that end of the carbon fiber spoke rod 1 engages with the inner wall surface of the head 2.

[0043] In this embodiment, the concave-convex structure 31 / 21 is wavy and spiral-shaped, but it is not limited to this. In other embodiments, the concave-convex structure includes a plurality of annular grooves spaced apart along the axial direction. The axial direction refers to the axial direction of the tooth cap or cap head.

[0044] In this embodiment, the carbon fiber spoke rod 1 is formed by rolling carbon sand sheets into a rod and then curing it. Before curing, foaming agent is inserted into the inside of both ends of the rod. During the curing process, the foaming agent expands when heated, which expands the walls around the ends of the rod, making them fit tightly against the inner walls of the tooth cap 3 and the cap head 2. Since the inner walls of the tooth cap 3 and the cap head 2 are respectively provided with a wavy spiral-shaped concave-convex structure 31 / 21, the walls around the ends of the rod will form a wavy spiral shape that matches it. Thus, the outer walls at both ends of the cured carbon fiber spoke rod 1 form an internal and external meshing state with the inner walls of the tooth cap 3 and the cap head 2 (i.e., forming a tooth-like meshing).

[0045] In this embodiment, the inner diameter of the cap 3 gradually decreases from its outer end to its inner end, and the inner diameter of the head 2 also gradually decreases from its outer end to its inner end. Therefore, the inner cavities of the cap 3 and the head 2 are approximately conical, and the difference in inner diameter between their inner and outer ends is approximately 1 mm. The outer ends of the cap 3 and the head 2 refer to the ends furthest from the middle of the carbon fiber spoke rod 1, while the inner ends of the cap 3 and the head 2 refer to the ends closer to the middle of the carbon fiber spoke rod 1. The carbon fiber spoke rod 1 is thicker in the middle and thinner at both ends.

[0046] This invention discloses a carbon fiber spoke. Because the outer walls of both ends of the carbon fiber spoke rod 1 form an inner-outer meshing state (i.e., a toothed engagement) with the inner walls of the tooth cap 3 and the cap head 2, respectively, and simultaneously, the inner diameter of the tooth cap 3 gradually decreases from its outer end to its inner end, and the inner diameter of the cap head 2 also gradually decreases from its outer end to its inner end, the carbon fiber spoke becomes increasingly tighter under tensile force, thereby greatly improving the tensile strength of the carbon fiber spoke. This invention, by using a carbon fiber spoke rod 1, significantly reduces the weight of bicycle spokes.

[0047] The present invention provides a carbon fiber spoke, which is manufactured using the aforementioned method for manufacturing a carbon fiber spoke. Therefore, the manufacturing method will not be described in detail here.

[0048] The above embodiments are only used to further illustrate a method for manufacturing carbon fiber spokes and carbon fiber spokes of the present invention. However, the present invention is not limited to the embodiments. Any simple modifications, equivalent changes and alterations made to the above embodiments based on the technical essence of the present invention shall fall within the protection scope of the technical solution of the present invention.

Claims

1. A method for manufacturing carbon fiber spokes, characterized in that: Includes the following steps: 1) Roll the carbon sand sheet into a rod and fill it with foaming agent at least at both ends; 2) Insert one end of the rod into the nut that can be connected to the rim, and insert the other end of the rod into the head that can be connected to the hub. The inner wall of the nut and the inner wall of the head are respectively provided with concave and convex structures. 3) The rod is heated and cured to form a carbon fiber spoke rod. During the curing process, the foaming agent expands when heated, which expands the side walls around the end of the rod so that the two ends of the rod are tightly attached to the inner walls of the tooth cap and the cap head, respectively. The outer wall surfaces of the two ends of the carbon fiber spoke rod are engaged with the inner wall surfaces of the tooth cap and the cap head, respectively.

2. The method for manufacturing carbon fiber spokes according to claim 1, characterized in that: Step 3) includes the following steps: 31) Place the pre-impregnated resin rod and its toothed cap and cap head into the molding groove of the molding die; 32) Place the molding die into the high-temperature curing equipment to cure the rod at high temperature; 33) After curing is complete, remove the molding mold, and take out the bar and its tooth cap and cap head to form the finished carbon fiber spoke.

3. The method for manufacturing carbon fiber spokes according to claim 2, characterized in that: The number of forming grooves is multiple, and these multiple forming grooves are arranged in at least one row, with each forming groove corresponding to a bar.

4. The method for manufacturing carbon fiber spokes according to claim 1, characterized in that: The concave-convex structure is wavy and spiral-shaped, or the concave-convex structure includes multiple annular grooves spaced apart along the axial direction.

5. The method for manufacturing carbon fiber spokes according to claim 1, characterized in that: The inner diameter of the dental cap gradually decreases from its outer end to its inner end; the inner diameter of the cap head gradually decreases from its outer end to its inner end.

6. The method for manufacturing carbon fiber spokes according to claim 1, characterized in that: The foaming agent is a black foaming agent; the carbon sand sheets are formed into bars using a rolling process.

7. A carbon fiber spoke, manufactured using the method for producing carbon fiber spokes according to any one of claims 1-6, comprising a carbon fiber spoke bar, a feed cap for connecting to a rim, and a head cap for connecting to a hub, characterized in that: The inner wall of the cap and the inner wall of the cap head are respectively provided with concave and convex structures. One end of the carbon fiber spoke rod is inserted into the cap, and the outer wall of that end of the carbon fiber spoke rod engages with the inner wall of the cap. The other end of the carbon fiber spoke rod is inserted into the cap head, and the outer wall of that end of the carbon fiber spoke rod engages with the inner wall of the cap head.

8. The carbon fiber spokes according to claim 7, characterized in that: The concave-convex structure is wavy and spiral-shaped, or the concave-convex structure includes multiple annular grooves spaced apart along the axial direction.

9. The carbon fiber spokes according to claim 7, characterized in that: The carbon fiber spoke rod is formed by rolling carbon sand sheets into a rod and then curing it; the carbon fiber spoke rod is thicker in the middle and thinner at both ends.

10. The carbon fiber spokes according to claim 7, characterized in that: The inner diameter of the dental cap gradually decreases from its outer end to its inner end; the inner diameter of the cap head gradually decreases from its outer end to its inner end.

Images