Carbon fiber wheel rim and manufacturing method thereof

Abstract

This invention discloses a carbon fiber wheel rim and its manufacturing method, comprising an annular carbon fiber inner frame and a carbon fiber outer frame. The carbon fiber inner frame is configured by pre-forming a pre-fabricated material into a preset shape to give the cross-section of the inner frame a U-shaped structure. The pre-fabricated material is made by spirally winding several carbon fiber strips pre-impregnated with epoxy resin at different preset winding angles onto an annular fixture and then cutting it circumferentially along the outer periphery of the annular fixture. The carbon fiber outer frame is attached to the open end of the carbon fiber inner frame, thereby combining the inner and outer frames to form the main structure of the carbon fiber wheel rim. The pre-fabricated material used to form the carbon fiber inner frame is obtained by wrapping several carbon fiber strips around an annular fixture at different winding angles and then performing a circumferential cutting process. Therefore, it can effectively improve the frontal and lateral rigidity of the carbon fiber inner frame, so as to maintain the overall strength stability of the carbon fiber wheel rim structure.

Description

Technical Field

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

[0002] In the current manufacturing process of carbon fiber bicycle rims, a single sheet of carbon fiber cloth pre-impregnated with epoxy resin is typically cut to the required size, and at least two layers of carbon fiber cloth are manually bonded onto a molding die. Then, the epoxy resin is heated to harden, thus shaping the carbon fiber cloth into the bicycle rim structure. However, the current carbon fiber rims manufactured by bonding are relatively complicated in terms of the cutting, stacking, and trimming of the carbon fiber cloth, which affects the overall production efficiency of the rim. Furthermore, the frontal and lateral rigidity of carbon fiber rims manufactured by the current bonding method is not good and needs to be further improved. Summary of the Invention

[0003] To address the shortcomings of existing technologies, this invention provides a carbon fiber wheel rim, which mainly solves the technical problems of poor frontal and lateral rigidity and low overall production efficiency of existing carbon fiber wheel rims manufactured by bonding.

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

[0005] A carbon fiber wheel rim includes an annular carbon fiber inner frame and a carbon fiber outer frame. The carbon fiber inner frame is configured to be pre-shaped by a pre-fabricated surface material to make the cross-section of the carbon fiber inner frame U-shaped. The pre-fabricated surface material is made by spirally winding several carbon fiber strips pre-impregnated with epoxy resin at different preset winding angles on an annular fixture and cutting them along the outer circumference of the annular fixture. The carbon fiber outer frame is connected to the open end of the carbon fiber inner frame, thereby making the carbon fiber inner frame and the carbon fiber outer frame combine to form the main structure of the carbon fiber wheel rim.

[0006] Furthermore, the prefabricated surface material is made by winding several carbon fiber strips at preset winding angles onto a ring fixture and then cutting them along the outer circumference of the ring fixture.

[0007] Furthermore, the prefabricated surface material is made by overlapping and winding several carbon fiber strips onto a ring fixture at a preset winding angle and then cutting them along the outer circumference of the ring fixture.

[0008] Furthermore, the prefabricated surface material is made by winding several carbon fiber strips alternately on a ring fixture at a preset winding angle and then cutting them along the outer circumference of the ring fixture.

[0009] Furthermore, the prefabricated surface material is made by spirally winding at least two carbon fiber strips pre-impregnated with epoxy resin onto a ring fixture at different preset winding angles and then cutting them open along the outer circumference of the ring fixture.

[0010] Furthermore, the angle between the carbon fiber strip and the tangent of the outer periphery of the annular fixture is defined as the winding angle of the carbon fiber strip on the annular fixture, which is 5° to 90°.

[0011] Furthermore, the width of the carbon fiber strip is 5mm to 20mm.

[0012] Based on the same inventive concept, the present invention also provides a manufacturing method for producing any of the above-described carbon fiber wheel rims, comprising the following steps: S1, spirally winding a carbon fiber strip pre-impregnated with epoxy resin onto an annular fixture at a first preset winding angle to form a first carbon fiber layer, and then spirally winding another carbon fiber strip pre-impregnated with epoxy resin onto the first carbon fiber layer at a second preset winding angle to form a second carbon fiber layer; after the carbon fiber strips are wound to a preset number of layers, the multi-layered composite carbon fiber layer is cut along the outer periphery of the annular fixture to obtain a pre-formed surface material; S2, fitting the pre-formed surface material onto an inner frame pre-formed fixture for further processing. Pre-molding: The pre-molded carbon fiber inner frame has a U-shaped cross-section. A long strip of air bag is inserted into the pre-molded carbon fiber inner frame from the open end and wraps around its outer circumference. Then, the pre-made carbon fiber outer frame is connected to the open end of the carbon fiber inner frame with epoxy resin to seal the open end of the carbon fiber inner frame. The air supply pipe of the air bag extends out of the carbon fiber outer frame. The air bag is inflated through the air supply pipe to support it between the carbon fiber inner frame and the carbon fiber outer frame for molding. S3: The carbon fiber inner frame and carbon fiber outer frame, which are connected as one piece, are placed in a molding mold for molding. Then, the air bag is deflated and removed from the air supply pipe hole of the carbon fiber outer frame to obtain the finished carbon fiber wheel rim.

[0013] Furthermore, in step S1, the winding angle of the carbon fiber strip forming the first carbon fiber layer on the annular fixture is 70° to 90°, while the winding angle of the second carbon fiber layer is 45° to 75°.

[0014] The above technical solution has the following advantages or beneficial effects:

[0015] In the carbon fiber wheel rim and its manufacturing method described in this invention, a prefabricated surface material is obtained by wrapping each carbon fiber strip with a ring fixture at different winding angles and then performing ring cutting. The prefabricated surface material is then pre-shaped into a carbon fiber inner frame according to a preset shape. A carbon fiber outer frame is attached to the open end of the carbon fiber inner frame to close its open end. Thus, the carbon fiber inner frame and the carbon fiber outer frame are combined after molding to form the main structure of the carbon fiber wheel rim. Compared with the existing bonding processing method, the carbon fiber inner frame can reduce the processing steps of cutting, stacking and trimming, thereby improving its production efficiency. At the same time, the prefabricated surface material used to form the carbon fiber inner frame is obtained by wrapping several carbon fiber strips with a ring fixture at different winding angles and then performing ring cutting. Therefore, it can effectively improve the frontal rigidity and lateral rigidity of the carbon fiber inner frame, so as to maintain the overall strength stability of the carbon fiber wheel rim structure. Attached Figure Description

[0016] Figure 1 This is a three-dimensional structural schematic diagram of the carbon fiber wheel rim according to Embodiment 1 of the present invention.

[0017] Figure 2 This is a structural cross-sectional view of the carbon fiber wheel rim according to Embodiment 1 of the present invention.

[0018] Figure 3 This is an exploded structural diagram of the carbon fiber wheel rim according to Embodiment 1 of the present invention.

[0019] Figure 4 This is a schematic diagram of the winding structure of the carbon fiber strip and the annular fixture in Embodiment 1 of the present invention.

[0020] Figure 5 This is a three-dimensional structural diagram of the inner frame preform fixture according to Embodiment 1 of the present invention.

[0021] Figure 6 This is a cross-sectional view of the assembly structure of the carbon fiber wheel rim and air bag according to Embodiment 1 of the present invention.

[0022] Figure 7 This is a schematic diagram of the winding structure of the carbon fiber strip and the annular fixture in Embodiment 2 of the present invention.

[0023] Figure 8 This is a schematic diagram of the winding structure of the carbon fiber strip and the annular fixture in Embodiment 3 of the present invention.

[0024] Label Explanation:

[0025] 1. Carbon fiber inner frame, 2. Carbon fiber outer frame, 3. Carbon fiber strip, 4. Circular fixture, 5. Inner frame pre-formed fixture, 6. Air bag, 61. Air supply pipe. Detailed Implementation

[0026] The present invention will be further described below with reference to the accompanying drawings and embodiments.

[0027] 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.

[0028] Example 1

[0029] Please refer to the appendix. Figure 1 To be continued Figure 6An embodiment of the present invention provides a carbon fiber wheel rim, including an annular carbon fiber inner frame 1 and a carbon fiber outer frame 2. The carbon fiber inner frame 1 is configured to be pre-shaped by a pre-fabricated surface material to make the cross-section of the carbon fiber inner frame 1 have a U-shaped structure. The pre-fabricated surface material is made by spirally winding several carbon fiber strips 3 pre-impregnated with epoxy resin in layers at different preset winding angles on an annular fixture 4 and cutting them around the outer periphery of the annular fixture 4. The carbon fiber outer frame 2 is connected to the open end of the carbon fiber inner frame 1, thereby making the carbon fiber inner frame 1 and the carbon fiber outer frame 2 combine to form the main structure of the carbon fiber wheel rim. It is understood that in this embodiment, a prefabricated surface material is obtained by wrapping each carbon fiber strip 3 around the annular fixture 4 at different winding angles and then performing a ring-cutting process. The prefabricated surface material is then pre-shaped into a carbon fiber inner frame 1 according to a preset shape. A carbon fiber outer frame 2 is attached to the open end of the carbon fiber inner frame 1 to close its open end. Thus, the carbon fiber inner frame 1 and the carbon fiber outer frame 2 are combined after molding to form the main structure of the carbon fiber wheel rim. Compared with the existing bonding processing method, the carbon fiber inner frame 1 can reduce the processing steps of cutting, stacking and trimming, which is conducive to improving its production efficiency. At the same time, the prefabricated surface material used to form the carbon fiber inner frame 1 is obtained by wrapping several carbon fiber strips 3 around the annular fixture 4 at different winding angles and then performing a ring-cutting process. Therefore, the frontal rigidity and lateral rigidity of the carbon fiber inner frame 1 can be effectively improved to maintain the overall strength stability of the carbon fiber wheel rim structure.

[0030] Please refer to the appendix. Figure 4 In one preferred embodiment, the prefabricated face material is preferably made by winding several carbon fiber strips 3 at preset winding angles onto an annular fixture 4 and then cutting them along the outer circumference of the annular fixture 4. (See attached image) Figure 4 The image shows only one layer. Multiple carbon fiber strips 3 are wound in layers at different winding angles to form a multi-carbon fiber composite that can completely cover the entire annular fixture 4. After being circumferentially cut along its outer perimeter, a piece of carbon fiber prefabricated material can be formed.

[0031] Please refer to the appendix. Figure 2 To be continued Figure 4 In one preferred embodiment, the prefabricated surface material is made by spirally winding at least two epoxy resin-impregnated carbon fiber strips 3 in layers onto an annular fixture 4 at different preset winding angles and then cutting along the outer circumference of the annular fixture 4. However, those skilled in the art will understand that in other embodiments, the prefabricated surface material can also be made by spirally winding three or more carbon fiber strips 3 in layers onto an annular fixture 4 at preset winding angles and then cutting along the outer circumference of the annular fixture 4. After each carbon fiber strip 3 is wound, a complete carbon fiber layer is formed in the annular fixture 4. Multiple carbon fiber strips 3 are wound in layers to form a multi-layer carbon fiber composite structure. Those skilled in the art can specifically set the number of composite layers of the carbon fiber layer of the prefabricated surface material according to specific needs, such as two, three, four, or more layers.

[0032] Please refer to the appendix. Figure 2 To be continued Figure 4 In one preferred embodiment, the angle between the carbon fiber strip 3 and the tangent of the outer periphery of the annular fixture 4 is defined as the winding angle of the carbon fiber strip 3 on the annular fixture 4, which is 5° to 90°. Preferably, the width of the carbon fiber strip 3 is 5mm to 20mm.

[0033] Please refer to the appendix. Figure 1 To be continued Figure 6 An embodiment of the present invention also provides a method for manufacturing carbon fiber wheel rims for any of the above embodiments, comprising the following steps: S1, a carbon fiber strip 3 pre-impregnated with epoxy resin is spirally wound onto an annular fixture 4 at a first preset winding angle to form a first carbon fiber layer, and then another carbon fiber strip 3 pre-impregnated with epoxy resin is spirally wound onto the first carbon fiber layer at a second preset winding angle to form a second carbon fiber layer. After the carbon fiber strip 3 is wound to a preset number of layers, the multi-layer composite carbon fiber layer is circumferentially cut along the outer periphery of the annular fixture 4 to obtain a pre-formed surface material; S2, the pre-formed surface material is fitted onto an inner frame pre-forming fixture 5 for pre-forming, so that the cross-section of the pre-formed carbon fiber inner frame 1 has a U-shaped structure, and a long strip-shaped air bag 6 is inserted from the opening... The pre-shaped carbon fiber inner frame 1 is embedded at the opening and surrounds it. Then, the pre-made carbon fiber outer frame 2 is connected to the opening of the carbon fiber inner frame 1 with epoxy resin to seal the opening of the carbon fiber inner frame 1. The air bag 6 is sealed in the U-shaped groove of the carbon fiber inner frame 1, and the air supply pipe 61 of the air bag 6 passes through the carbon fiber outer frame 2. The air bag 6 is inflated through the air supply pipe 61 to support it between the carbon fiber inner frame 1 and the carbon fiber outer frame 2, so as to prevent the hollow part between the carbon fiber inner frame 1 and the carbon fiber outer frame 2 from collapsing, so as to facilitate the forming of carbon fiber wheel rims; S3, the carbon fiber inner frame 1 and carbon fiber outer frame 2 connected as a whole are placed in the forming mold for forming processing. Then, the air bag 6 is deflated and the air bag 6 is pulled out from the perforation of the air supply pipe of the carbon fiber outer frame 2 to obtain the finished carbon fiber wheel rim.

[0034] In one preferred embodiment, in step S1, the winding angle of the carbon fiber strip 3 forming the first carbon fiber layer on the annular fixture 4 is 70° to 90°, while the winding angle of the second carbon fiber layer is 45° to 75°. Furthermore, in other embodiments, if the prefabricated surface material is formed by a composite of three or more carbon fiber layers, then the winding angle of the carbon fiber strip forming the corresponding carbon fiber layer should also be different from the winding angle of the carbon fiber strips in other carbon fiber layers.

[0035] Example 2

[0036] Please refer to the appendix. Figure 7The difference between this embodiment and Embodiment 1 is that the prefabricated surface material is made by overlapping and winding several carbon fiber strips 3 onto the annular fixture 4 at a preset winding angle and then cutting them along the outer periphery of the annular fixture 4.

[0037] Example 3

[0038] Please refer to the appendix. Figure 8 The difference between this embodiment and Embodiment 1 is that the prefabricated surface material is made by winding several carbon fiber strips 3 alternately on the annular fixture 4 at a preset winding angle and then cutting them along the outer circumference of the annular fixture 4.

[0039] 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 manufacturing carbon fiber wheel rims, characterized in that: The carbon fiber wheel rim includes an annular carbon fiber inner frame (1) and a carbon fiber outer frame (2), and the manufacturing method includes the following steps: S1, a carbon fiber strip (3) pre-impregnated with epoxy resin is spirally wound onto an annular fixture (4) at a first preset winding angle to form a first carbon fiber layer. Then another carbon fiber strip (3) pre-impregnated with epoxy resin is spirally wound onto the first carbon fiber layer at a second preset winding angle to form a second carbon fiber layer. After the carbon fiber strip (3) is wound according to the preset number of layers, the multi-layer composite carbon fiber layer is cut along the outer periphery of the annular fixture (4) to obtain the prefabricated surface material. S2, the prefabricated material is placed on the inner frame pre-forming fixture (5) for pre-forming, so that the cross-section of the pre-formed carbon fiber inner frame (1) is U-shaped. A long strip of air bag (6) is inserted into the pre-formed carbon fiber inner frame (1) from the opening end and wrapped around its outer perimeter. Then, the prefabricated carbon fiber outer frame (2) is connected to the opening end of the carbon fiber inner frame (1) through epoxy resin to close the opening end of the carbon fiber inner frame (1). The air supply pipe (61) of the air bag (6) passes through the carbon fiber outer frame (2). The air bag (6) is inflated through the air supply pipe (61) to expand and support it between the carbon fiber inner frame (1) and the carbon fiber outer frame (2) for forming. S3, the carbon fiber inner frame (1) and carbon fiber outer frame (2) connected as one piece are placed in the molding mold for molding processing, and then the air bag (6) is deflated and the air bag (6) is pulled out from the air pipe perforation of the carbon fiber outer frame (2) to obtain the finished carbon fiber wheel rim.

2. The manufacturing method according to claim 1, characterized in that: In step S1, the winding angle of the carbon fiber strip (3) forming the first carbon fiber layer on the annular fixture (4) is 70°~90°, while the winding angle of the second carbon fiber layer is 45°~75°.

3. The manufacturing method according to claim 1, characterized in that: The prefabricated surface material is made by spirally winding several carbon fiber strips (3) pre-impregnated with epoxy resin in layers on an annular fixture (4) at different preset winding angles and cutting them along the outer circumference of the annular fixture (4). The carbon fiber outer frame (2) is connected to the opening end of the carbon fiber inner frame (1), so that the carbon fiber inner frame (1) and the carbon fiber outer frame (2) are combined to form the main structure of the carbon fiber wheel rim. The prefabricated surface material is made by spirally winding at least two carbon fiber strips (3) pre-impregnated with epoxy resin in layers on an annular fixture (4) at different preset winding angles and cutting them along the outer circumference of the annular fixture (4).

4. The manufacturing method according to claim 3, characterized in that: The prefabricated surface material is made by winding several carbon fiber strips (3) at preset winding angles onto an annular fixture (4) and cutting them around the outer periphery of the annular fixture (4).

5. The manufacturing method according to claim 3, characterized in that: The prefabricated surface material is made by overlapping and winding several carbon fiber strips (3) at a preset winding angle onto a ring jig (4) and cutting them along the outer circumference of the ring jig (4).

6. The manufacturing method according to claim 3, characterized in that: The prefabricated surface material is made by winding several carbon fiber strips (3) alternately on the annular fixture (4) at a preset winding angle and cutting them along the outer circumference of the annular fixture (4).

7. The manufacturing method according to any one of claims 3 to 6, characterized in that: The angle between the carbon fiber strip (3) and the tangent of the outer periphery of the ring fixture (4) is defined as the winding angle of the carbon fiber strip (3) on the ring fixture (4), which is 5°~90°.

8. The manufacturing method according to any one of claims 3 to 6, characterized in that: The width of the carbon fiber strip (3) is 5mm~20mm.

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