A carbon fiber spoke and a production method thereof, a bicycle rim, and a bicycle

Abstract

The application discloses a carbon fiber spoke, a production method thereof, a bicycle wheel and a bicycle, and comprises the following steps: S1, preparing a long strip-shaped and unformed carbon fiber rod; S2, forming the carbon fiber rod into a carbon fiber rod semi-product with a middle part being formed and both ends being unformed through one-time forming processing; S3, cleaning and removing the epoxy resin in the unformed part at both ends of the carbon fiber rod semi-product by using a resin cleaning agent; S4, placing the connecting ends of the first connecting piece and the second connecting piece into the carbon fiber filaments at both ends respectively, and recoating the epoxy resin after the carbon fiber filaments are straightened; S5, wrapping and reinforcing the outer layer of the connecting end by using angle yarn; and S6, performing two-time forming processing as a whole. The carbon fiber filament distribution at the connecting part of the carbon fiber rod is controllable, the first connecting piece and the second connecting piece can be uniformly wrapped, the mechanical strength of the connecting part is improved, and the use stability and safety of the carbon fiber spoke product are effectively ensured.

Description

Technical Field

[0001] This invention relates to the field of bicycle technology, specifically to a carbon fiber spoke and its manufacturing method, a bicycle rim, and a bicycle. Background Technology

[0002] Traditional bicycle spokes are generally made of stainless steel, with one end connected to the hub and the other to the rim. However, traditional stainless steel spokes are relatively heavy, which is not conducive to the lightweight requirements of bicycles. More advanced bicycle spoke technology uses a carbon fiber spoke body as the main body, with metal lugs and bezels integrally formed by heating and curing them in a single molding process, thus creating the finished carbon fiber spoke. However, tests have shown that carbon fiber spokes produced by this one-piece molding method are prone to low connection strength at the joints between the ends of the carbon fiber spoke body and the lugs and bezels, affecting the lifespan of the carbon fiber spoke product. Summary of the Invention

[0003] To address the shortcomings of existing technologies, this invention provides a method for producing carbon fiber spokes. The main solution is to address the technical problem that existing one-time molding methods often result in low connection strength at the ends of the carbon fiber spoke body where it connects to the tooth cap and the cap head, thus affecting the lifespan of the carbon fiber spoke product.

[0004] To achieve the above objectives, the present invention is implemented through the following technical solution:

[0005] A method for producing carbon fiber spokes includes the following steps:

[0006] S1, Prepare long, unformed carbon fiber rods according to preset dimensions;

[0007] S2, place the unformed carbon fiber rod in the first forming mold, and perform a one-time forming process only on the middle main body of the carbon fiber rod, so that the carbon fiber rod forms a carbon fiber rod semi-finished product with the middle part formed and the two ends remaining unformed.

[0008] S3, use resin cleaning agent to clean and remove the epoxy resin in the unformed part at both ends of the carbon fiber rod semi-finished product, so that the carbon fiber filaments at both ends of the carbon fiber rod semi-finished product are exposed.

[0009] S4. Place the pre-made first connector and second connector into the carbon fiber filaments at both ends of the carbon fiber rod semi-finished product, straighten the carbon fiber filaments so that they are evenly and flatly arranged on the circumferential surface of the corresponding connecting ends of the first connector and second connector, and then re-coat the straightened carbon fiber filaments with epoxy resin to evenly wrap the connecting ends of the first connector and second connector.

[0010] S5, use angled yarn to wrap and reinforce the outer layer of the connection between the first connector and the second connector;

[0011] S6, the carbon fiber rod semi-finished product with the first connector and the second connector connected to both ends is placed in the second molding mold, and the whole is subjected to secondary molding processing to obtain a carbon fiber spoke with the first connector, the second connector and the molded carbon fiber rod as an integral connection structure.

[0012] Furthermore, in step S1, the orientation of the carbon fiber filaments in the carbon fiber rod is consistent with the axial direction of the carbon fiber rod.

[0013] Furthermore, in step S3, the resin cleaning agent is an organic solvent, preferably methyl ethyl ketone (MEK).

[0014] Furthermore, in step S5, the angle yarn is a carbon fiber yarn sheet structure in which the direction of the carbon fiber is at an angle of 22° to 60° with the axial direction of the carbon fiber rod.

[0015] Furthermore, the first connector is a nut for connecting to the rim, and the second connector is a headpiece for connecting to the hub. The nut and headpiece are made of metal.

[0016] Furthermore, the cap and the top of the cap are made of stainless steel or aluminum alloy.

[0017] Furthermore, the connecting ends of the tooth cap and the cap head used to connect the carbon fiber rod are formed with threaded structures that can improve the connection strength between the tooth cap and the cap head and the formed carbon fiber rod.

[0018] Based on the same inventive concept, the present invention also provides a carbon fiber spoke, which is produced by any of the carbon fiber spoke production methods described above.

[0019] Based on the same inventive concept, the present invention also provides a bicycle rim, including the aforementioned carbon fiber spokes.

[0020] Based on the same inventive concept, the present invention also provides a bicycle, including the above-described bicycle rim.

[0021] The above technical solution has the following advantages or beneficial effects:

[0022] In the carbon fiber spokes and their production method, bicycle rims, and bicycles described in this invention, compared to carbon fiber spokes produced by a one-time molding method, the carbon fiber filament distribution at the connection points between the two ends of the carbon fiber spoke body and the first and second connecting members is controllable and can be uniformly wrapped. Compared to the technical solution of forming insertion structures at both ends of the carbon fiber rod, this effectively avoids the uneven distribution of carbon fiber filaments at the openings caused by forming insertion structures, which would affect the mechanical strength of the two ends of the formed carbon fiber rod. Furthermore, after the carbon fiber filaments are uniformly straightened and coated with epoxy resin again, angle yarn is used to reinforce the outer layer of the wrapping area, which further improves the mechanical strength of the connection point. This allows the first and second connecting members to be firmly connected to both ends of the formed carbon fiber spoke body without the risk of loosening or falling off, thereby effectively ensuring the stability and safety of the carbon fiber spoke product in use. Attached Figure Description

[0023] Figure 1 This is a three-dimensional structural diagram of the carbon fiber spokes according to an embodiment of the present invention.

[0024] Figure 2 This is an exploded three-dimensional structural diagram of the carbon fiber spokes according to an embodiment of the present invention.

[0025] Figure 3 This is a cross-sectional view of the carbon fiber spokes according to an embodiment of the present invention.

[0026] Figure 4 yes Figure 3 A magnified view of section A in the image.

[0027] Label Explanation:

[0028] 1. Carbon fiber rod; 2. First connector; 3. Second connector. Detailed Implementation

[0029] The present invention will be further described below with reference to the accompanying drawings and embodiments.

[0030] In the description of this invention, it should be understood that the terms "upper", "lower", "front", "rear", "left", "right", "top", "bottom", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this invention.

[0031] Please refer to the appendix. Figure 1 To be continued Figure 4An embodiment of the present invention provides a method for producing carbon fiber spokes, comprising the following steps: S1, preparing a long, unformed, dense carbon fiber rod 1 according to a preset size; S2, placing the unformed carbon fiber rod 1 in a first forming mold, and performing a one-time forming process only on the middle main body of the carbon fiber rod 1, so that the carbon fiber rod 1 forms a carbon fiber rod semi-finished product with the middle formed and the two ends remaining unformed; S3, using a resin cleaning agent to clean and remove the epoxy resin in the unformed parts at both ends of the carbon fiber rod semi-finished product, so that the carbon fiber filaments at both ends of the carbon fiber rod semi-finished product are exposed; S4, placing the connecting ends of the pre-made first connector 2 and the second connector 3 into the carbon fiber filaments at both ends of the carbon fiber rod semi-finished product, respectively, and straightening the carbon fibers. The carbon fiber filaments (each carbon fiber filament extends along the axial direction of the carbon fiber rod 1, or along the original straight extension direction of each carbon fiber filament) are arranged evenly and flatly on the circumferential surface of the corresponding connecting ends of the first connector 2 and the second connector 3. Then, epoxy resin is recoated on the straightened carbon fiber filaments to evenly wrap the connecting ends of the first connector 2 and the second connector 3. S5, angle yarn is used to cover and reinforce the outer layer of the wrapping area of ​​the connecting ends of the first connector 2 and the second connector 3. S6, the carbon fiber rod semi-finished product with the first connector 2 and the second connector 3 connected to both ends is placed in the second molding mold and subjected to secondary molding processing to obtain a carbon fiber spoke with the first connector 2, the second connector 3 and the molded carbon fiber rod 1 as an integral connection structure. It is understood that in this embodiment, a secondary molding method is used to manufacture carbon fiber spoke products. Specifically, the pre-made dense long rod-shaped carbon fiber rod 1 is further shaped and processed to form the main body in the middle, which is then heated and cured. A section is left at each end to retain the original structure before molding, thus forming a carbon fiber rod semi-finished product. Then, a resin cleaning agent is used to clean and remove the epoxy resin in the unmolded parts at both ends of the carbon fiber rod semi-finished product, leaving only pure carbon fiber filaments. Next, the connecting ends of the first connector 2 and the second connector 3 are respectively placed into the carbon fiber filaments at both ends of the carbon fiber rod semi-finished product, and the carbon fiber filaments are straightened so that the connecting ends of the first connector 2 and the second connector 3 are evenly wrapped by the carbon fiber filaments evenly arranged in a straight direction. Then, epoxy resin is recoated for wrapping and fixing. Next, angle yarn is used to cover and reinforce the outer layer of the wrapping at the connecting ends. Then, the whole thing can be placed in the second molding mold for secondary molding processing to obtain the carbon fiber spoke product. Compared to carbon fiber spokes produced by one-time molding, the carbon fiber filament distribution at the connection points between the two ends of the carbon fiber spoke body 1 and the first connector 2 and the second connector 3 in the two-time molding method is controllable and can be uniformly wrapped. Compared to the technical solution of forming insertion holes at both ends of the carbon fiber rod, it can effectively avoid the uneven distribution of carbon fiber filaments at the opening due to the forming insertion hole structure, which would affect the mechanical strength of both ends of the formed carbon fiber rod.Furthermore, in step S5, after the carbon fiber filaments are evenly straightened and coated with epoxy resin again, angle yarn is used to wrap and reinforce the outer layer of the wrapping area. This helps to further improve the mechanical strength of the connection, so that the first connector 2 and the second connector 3 can be firmly connected to both ends of the formed carbon fiber spoke body 1 without the risk of loosening or falling off, thereby effectively ensuring the stability and safety of the carbon fiber spoke product.

[0032] In one preferred embodiment, preferably, in step S1, the orientation of the carbon fiber filaments in the carbon fiber rod 1 is consistent with the axial direction of the carbon fiber rod 1. That is, the carbon fiber filaments extend along the length direction of the carbon fiber rod 1.

[0033] In one preferred embodiment, preferably, in step S3, the resin cleaning agent is an organic solvent, preferably methyl ethyl ketone (MEK). However, those skilled in the art will understand that in other embodiments, the resin cleaning agent is not limited to the specific implementation disclosed in this embodiment, and may also be other organic solvents that have a similar ability to clean epoxy resin as MEK.

[0034] In one preferred embodiment, preferably, in step S5, the angle yarn is a carbon fiber yarn sheet structure in which the direction of the carbon fiber is at an angle of 22° to 60° with the axial direction of the carbon fiber rod 1.

[0035] Please refer to the appendix. Figure 1 To be continued Figure 4 In one preferred embodiment, the first connector 2 is a nut for connection with the rim, and the second connector 3 is a headpiece for connection with the hub. Both the nut and headpiece are made of metal. Preferably, in this embodiment, the nut and headpiece are made of stainless steel or aluminum alloy. However, those skilled in the art should understand that in other embodiments, the nut and headpiece are not limited to the specific implementation disclosed in this embodiment and may also be made of other metal materials. Those skilled in the art can design according to specific needs.

[0036] Please refer to the appendix. Figure 1 To be continued Figure 4 In one preferred embodiment, the connecting ends of the toothed cap and the cap head used to connect to the carbon fiber rod 1 are both formed with threaded structures that can improve the connection strength between the toothed cap and the cap head and the formed carbon fiber rod 1. It can be understood that by providing threaded structures on the connecting ends of the toothed cap and the cap head, the integral connection structure formed by the toothed cap and the cap head and the carbon fiber rod can be more stable, which can effectively reduce the risk of the toothed cap and the cap head falling off from both ends of the formed carbon fiber rod 1, thereby improving the stability and safety of the carbon fiber spoke product.

[0037] Please refer to the appendix. Figure 1 To be continued Figure 4An embodiment of the present invention also provides a carbon fiber spoke, which is produced by the carbon fiber spoke production method of any of the above embodiments.

[0038] Furthermore, one embodiment of the present invention also provides a bicycle rim, including the aforementioned carbon fiber spokes.

[0039] Furthermore, one embodiment of the present invention also provides a bicycle including the bicycle rim described above.

[0040] The above-described embodiments are only used to illustrate the technical solutions of the present invention, and are not intended to limit it. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features therein. These modifications or substitutions do not cause the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of the present invention. Therefore, all other embodiments obtained by those skilled in the art without creative effort are within the protection scope of the present invention.

Claims

1. A method for producing carbon fiber spokes, characterized in that: Includes the following steps: S1, Prepare long and unformed carbon fiber rods (1). S2, the unformed carbon fiber rod (1) is placed in the first molding mold, and only the middle main body of the carbon fiber rod (1) is molded once, so that the carbon fiber rod (1) forms a carbon fiber rod semi-finished product with the middle part molded and the two ends remaining unformed. S3, use resin cleaning agent to clean and remove the epoxy resin in the unformed part at both ends of the carbon fiber rod semi-finished product, so that the carbon fiber filaments at both ends of the carbon fiber rod semi-finished product are exposed. S4, insert the connecting ends of the first connector (2) and the second connector (3) into the carbon fiber filaments at both ends of the carbon fiber rod semi-finished product, straighten the carbon fiber filaments so that they are evenly and flatly arranged on the circumferential surface of the corresponding connecting ends of the first connector (2) and the second connector (3), and then re-coat the straightened carbon fiber filaments with epoxy resin to evenly wrap the connecting ends of the first connector (2) and the second connector (3). S5, use angle yarn to wrap and reinforce the outer layer of the connection between the first connector (2) and the second connector (3); S6, the carbon fiber rod semi-finished product with the first connector (2) and the second connector (3) connected to both ends respectively is placed in the second molding mold and the whole is subjected to secondary molding process to obtain carbon fiber spokes with the first connector (2), the second connector (3) and the molded carbon fiber rod (1) as an integral connection structure. Among them, the connecting ends of the tooth cap and the cap head used to connect the carbon fiber rod (1) are formed with threaded structures that can improve the connection strength between the tooth cap and the cap head and the formed carbon fiber rod (1).

2. The method for producing carbon fiber spokes according to claim 1, characterized in that: In step S1, the direction of the carbon fiber filaments in the carbon fiber rod (1) is consistent with the axial direction of the carbon fiber rod (1).

3. The method for producing carbon fiber spokes according to claim 1, characterized in that: In step S3, the resin cleaning agent is an organic solvent.

4. The method for producing carbon fiber spokes according to claim 3, characterized in that: The resin cleaning agent is methyl ethyl ketone (MEK).

5. The method for producing carbon fiber spokes according to claim 1, characterized in that: In step S5, the angle yarn is a carbon fiber yarn sheet structure in which the direction of the carbon fiber is at an angle of 22° to 60° with the axial direction of the carbon fiber rod (1).

6. The method for producing carbon fiber spokes according to any one of claims 1 to 5, characterized in that: The first connector (2) is a toothed cap for connecting with the rim, and the second connector (3) is a cap for connecting with the hub. The toothed cap and the cap are made of metal.

7. The method for producing carbon fiber spokes according to claim 6, characterized in that: The cap and hat head are made of stainless steel or aluminum alloy.

8. A carbon fiber spoke, characterized in that: It is produced by the method of producing carbon fiber spokes according to any one of claims 1 to 7.

9. A bicycle rim, characterized in that: Includes the carbon fiber spokes as described in claim 8.

10. A bicycle, characterized in that: Including the bicycle rim as described in claim 9.

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