A carbon fiber bicycle processing method

Abstract

The present invention relates to a carbon fiber bicycle processing method, which comprises processing a bicycle front fork assembly, a bicycle rear fork assembly, and a bicycle frame assembly respectively; assembling the bicycle front fork assembly and the bicycle rear fork assembly to two ends of the bicycle frame assembly respectively to obtain a carbon fiber bicycle finished product; wherein the bicycle frame assembly comprises a frame shell and a frame accessory module; the frame accessory module is assembled on the frame shell; and the processing method of the frame shell comprises the following steps: S1, pre-treating a frame mold to obtain a pre-treated frame mold; S2, placing a frame preform into the frame mold and covering the mold; S3, closing the closed frame mold; and S4, blowing the closed frame mold to obtain a mold with a formed product. The processing method provided by the present invention not only saves raw materials, but also improves the qualified rate of finished products, thereby significantly reducing the cost of the product.

Description

Technical Field

[0001] The invention belongs to the technical field of carbon fiber bicycles, and in particular relates to a carbon fiber bicycle processing method. Background Art

[0002] Carbon fiber frames are characterized by their lightness, excellent rigidity, and impact absorption. However, fully utilizing these exceptional properties is technically challenging, and quality varies significantly between manufacturers. Carbon fiber frames offer advantages not found in other materials, allowing for lightweight bicycles weighing around 8-9 kg. These lightweight carbon fiber frames are particularly effective when climbing hills, providing a smooth and pleasurable ascent, unlike some lightweight aluminum alloy frames, which can cause a pullback when climbing.

[0003] However, the current carbon fiber bicycles are difficult to promote on a large scale and expand the market due to their high cost. The reasons for the high cost are: firstly, the high cost of the materials themselves, and secondly, the low level of manufacturing technology of carbon fiber bicycles, and the low product qualification rate further increase the cost of the finished product. Summary of the Invention

[0004] (1) Technical issues to be solved

[0005] In order to solve the above problems in the prior art, the present invention provides a carbon fiber bicycle processing method, which not only saves raw materials but also improves the qualified rate of finished products, thereby significantly reducing the cost of the product.

[0006] (2) Technical solution

[0007] In order to achieve the above objectives, the main technical solutions adopted by the present invention include:

[0008] A carbon fiber bicycle processing method, which processes a bicycle front fork assembly, a bicycle rear fork assembly and a bicycle frame assembly respectively;

[0009] Assembling a bicycle front fork assembly and a bicycle rear fork assembly to two ends of the bicycle frame assembly to obtain a finished carbon fiber bicycle;

[0010] Wherein, the bicycle frame assembly comprises: a frame shell and a frame accessory module;

[0011] The frame accessory module is assembled on the frame shell;

[0012] The processing method of the frame shell comprises the following steps:

[0013] S1, pre-treating the frame mold to obtain a pre-treated frame mold;

[0014] S2. Place the frame preform into the frame mold and cover the mold; the frame preform is a multi-layer carbon fiber sheet layer attached to the outer layer of the inner mold core; the inner mold core can be pneumatically shaped and is composed of resin and silicone;

[0015] S3, closing the frame mold with the completed cover mold;

[0016] S4, blowing air into the inner mold core of the closed frame mold, attaching carbon fiber sheets, and then hot pressing to obtain a mold with a molded product;

[0017] S5. Cooling the mold with the molded product and then opening the mold to remove the molded frame shell product;

[0018] S6. Repair and quality inspect the formed frame shell products.

[0019] Preferably, when the frame mold in step S1 is a newly used mold, the following steps are further included:

[0020] Heat the frame mold to 130-150℃;

[0021] The heated frame mold is blown away to remove debris, and then a release agent is applied inside the frame mold.

[0022] Preferably, when the frame mold is a new mold in step S1, the following steps are further included:

[0023] Wipe off the oil stains on the frame mold;

[0024] Brush the film-washing agent on the frame mold;

[0025] Apply release agent to the frame mold;

[0026] Clean and dry the frame mold;

[0027] Cool or heat the frame mold to 40-60℃;

[0028] The heated frame mold is blown away to remove debris, and then a release agent is applied inside the frame mold.

[0029] Preferably, when the frame mold in step S1 is a mold that has not been used for more than one week, the following steps are further included:

[0030] Brush the film-washing agent on the frame mold;

[0031] Apply release agent to the frame mold;

[0032] Clean and dry the frame mold;

[0033] Cool or heat the frame mold to 40-60℃;

[0034] The heated frame mold is blown away to remove debris, and then a release agent is applied inside the frame mold.

[0035] Preferably, the step S4 further comprises: placing a positioning pin on the frame mold that has undergone the mold clamping process, and then pushing the frame mold onto a pallet on the forming table;

[0036] The frame mold is connected to the air duct and the inner mold core inside the frame mold is inflated for hot pressing molding.

[0037] Preferably, the step S5 further comprises: unplugging the air connection pipe, pulling out the frame mold, and pushing the frame mold to a cold press table for cooling;

[0038] After cooling is completed, the frame mold is pulled down from the cold press table and the mold is ready to be opened to take out the molded frame shell product.

[0039] Preferably, the step S6 further comprises: inspecting the appearance of the frame shell product, wherein the technician finally confirms the appearance of the molded body and immediately improves any abnormalities;

[0040] The confirmed or improved frame shell products will be sent to QC for inspection.

[0041] Preferably, the bicycle front fork assembly comprises: a front fork frame, a front wheel unit and a steering frame unit;

[0042] The front fork frame is connected to the front end of the frame shell;

[0043] The front wheel unit and the bogie unit are respectively mounted on the lower portion and the upper portion of the front fork frame.

[0044] Preferably, the bicycle rear fork assembly comprises: a rear fork frame, a transmission unit and a rear wheel unit;

[0045] The rear fork frame is connected to the rear end of the frame shell;

[0046] The transmission unit and the rear wheel unit are both arranged on the rear fork frame;

[0047] The transmission unit is in transmission connection with the rear wheel unit.

[0048] Preferably, the frame accessory module includes: an electronic control module, a battery module, a motor module and a seat module;

[0049] The electronic control module, the battery module, the motor module and the seat module are all arranged on the frame shell;

[0050] The electric control module is respectively controlled and connected with the battery module and the motor module;

[0051] The battery module is connected to the motor module for power supply;

[0052] The motor module is drivingly connected to the transmission unit.

[0053] (3) Beneficial effects

[0054] The beneficial effects of the present invention are as follows: the carbon fiber bicycle processing method provided by the present invention has the following beneficial effects:

[0055] The processing method provided by the present application not only saves raw materials, but also greatly improves the qualified rate of finished products, thereby significantly reducing the cost of products. BRIEF DESCRIPTION OF THE DRAWINGS

[0056] Figure 1 A schematic diagram of the processing flow of a carbon fiber bicycle frame shell in a processing method provided by the present invention;

[0057] Figure 2 A structural schematic diagram of a carbon fiber bicycle frame shell in a carbon fiber bicycle processing method provided by the present invention;

[0058] Figure 3 This is a structural schematic diagram of a carbon fiber bicycle frame shell in a carbon fiber bicycle processing method provided by the present invention.

[0059] [Description of Reference Numerals]

[0060] 1: Front fork mounting hole; 2: Saddle mounting hole; 3: Rear fork mounting hole; 4: Motor mounting slot; 5: Battery mounting slot; 6: First shock absorber mounting hole; 7: Second shock absorber mounting hole. DETAILED DESCRIPTION

[0061] In order to better explain the present invention and facilitate understanding, the present invention is described in detail below through specific implementation methods in conjunction with the accompanying drawings.

[0062] like Figure 1 As shown: This embodiment discloses a carbon fiber bicycle processing method, which processes a bicycle front fork assembly, a bicycle rear fork assembly and a bicycle frame assembly respectively; the bicycle front fork assembly and the bicycle rear fork assembly are respectively assembled to the two ends of the bicycle frame assembly to obtain a carbon fiber bicycle finished product; wherein, the bicycle frame assembly includes: a frame shell and a frame accessory module; the frame accessory module is assembled on the frame shell.

[0063] The processing method of the frame shell described in this embodiment includes the following steps:

[0064] S1, pre-treating the frame mold to obtain a pre-treated frame mold;

[0065] S2. Place the frame preform into the frame mold and cover the mold; the frame preform is a multi-layer carbon fiber sheet layer attached to the outer layer of the inner mold core; the inner mold core can be pneumatically shaped and is composed of resin and silicone;

[0066] S3, closing the frame mold with the completed cover mold;

[0067] S4, blowing air into the inner mold core of the closed frame mold, attaching carbon fiber sheets, and then hot pressing to obtain a mold with a molded product;

[0068] S5. Cooling the mold with the molded product and then opening the mold to remove the molded frame shell product;

[0069] S6, repair and inspect the molded frame shell product. In this embodiment, when the frame mold in step S1 is a newly used mold, the following steps are also included:

[0070] Heat the frame mold to 130-150℃;

[0071] The heated frame mold is blown away to remove debris, and then a release agent is applied inside the frame mold.

[0072] In this embodiment, when the frame mold is a new mold, step S1 further includes the following steps:

[0073] Wipe off the oil stains on the frame mold;

[0074] Brush the film-washing agent on the frame mold;

[0075] Apply release agent to the frame mold;

[0076] Clean and dry the frame mold;

[0077] Cool or heat the frame mold to 40-60℃;

[0078] The heated frame mold is blown away to remove debris, and then a release agent is applied inside the frame mold.

[0079] In this embodiment, when the frame mold has not been used for more than one week in step S1, the following steps are further included:

[0080] Brush the film-washing agent on the frame mold;

[0081] Apply release agent to the frame mold;

[0082] Clean and dry the frame mold;

[0083] Cool or heat the frame mold to 40-60℃;

[0084] The heated frame mold is blown away to remove debris, and then a release agent is applied inside the frame mold.

[0085] In this embodiment, step S4 further includes: placing a positioning pin on the frame mold that has undergone the mold clamping process, and then pushing the frame mold onto a pallet on the forming table;

[0086] The frame mold is connected to the air duct and the inner mold core inside the frame mold is inflated for hot pressing molding.

[0087] In this embodiment, step S5 further includes: unplugging the air connection pipe, pulling out the frame mold, and pushing the frame mold to a cold press table for cooling;

[0088] After cooling is completed, the frame mold is pulled down from the cold press table and the mold is ready to be opened to take out the molded frame shell product.

[0089] In this embodiment, step S6 further includes: inspecting the appearance of the frame shell product, where the technician finally confirms the appearance of the molded body and immediately makes improvements to any abnormalities;

[0090] The confirmed or improved frame shell products will be sent to QC for inspection.

[0091] The bicycle front fork assembly in this embodiment includes: a front fork frame, a front wheel unit and a steering frame unit; the front fork frame is connected to the front end of the frame shell; the front wheel unit and the steering frame unit are respectively assembled on the lower part and the upper part of the front fork frame.

[0092] The bicycle rear fork assembly in this embodiment includes: a rear fork frame, a transmission unit and a rear wheel unit; the rear fork frame is connected to the rear end of the frame shell; the transmission unit and the rear wheel unit are both arranged on the rear fork frame; the transmission unit and the rear wheel unit are in transmission connection.

[0093] The frame accessory module in this embodiment includes: an electronic control module, a battery module, a motor module and a seat module; the electronic control module, the battery module, the motor module and the seat module are all arranged on the frame shell; the electronic control module is respectively controlled and connected to the battery module and the motor module; the battery module is connected to the motor module for power supply; and the motor module is driven and connected to the transmission unit.

[0094] The carbon fiber processing in this application adopts the hot pressing molding process. The specific process flow is:

[0095] 1. According to the carbon fiber bicycle frame, pre-design the inner membrane core structure (inner mold core combined with silicone and resin), outer mold structure, movable block structure, front fork locating pin structure, pin structure at the seat, etc. of the carbon fiber bicycle frame.

[0096] 2. The carbon fiber sheets are cut into pieces according to the preset shape and pasted to the outer surface of the inner mold core filled with gas silicone and resin to form a carbon fiber layer.

[0097] 3. Measure, repair and shape the carbon fiber on the surface of the inner mold core to achieve the expected size.

[0098] 4. Release some of the gas before placing the inner mold core into the hot pressing mold to make it easier to place the prefabricated part into the mold.

[0099] 5. Assemble the core detachable components such as the movable block structure, the front fork locating pin structure, and the seat pin structure (the space inside the battery box of the frame is composed of the movable block structure. The problem of the undercut formed inside the prefabricated part is solved by combining multiple groups of movable blocks and prefabricating the movable blocks with protrusions inside. The movable blocks with protrusions on both sides are installed first, and the middle movable block is wedged in by setting the wedge-shaped inclined surface in conjunction with the movable blocks on both sides).

[0100] 6. After closing the mold, inflate the inner film core for the second time to make the preform in the mold full as a whole.

[0101] 7. Hot pressing molding: hot pressing molding according to preset temperature, pressure, time and other conditions.

[0102] 8. After forming, take it out from the mold and remove the movable block structure, front fork positioning pin structure, seat pin structure, etc.

[0103] 9. Machining, internal hole drilling, external trimming, grinding and other surface treatments,

[0104] 10. Dimension and shape inspection; 11. Surface painting and baking varnish; 12. Finished product inspection and packaging.

[0105] like Figure 2 and Figure 3 As shown: the frame shell in this embodiment is provided with a front fork mounting hole 1, a seat mounting hole 2, a rear fork mounting hole 3, a motor mounting slot 4, a battery mounting slot 5, a first shock absorber mounting hole 6, and a second shock absorber mounting hole 7.

[0106] Among them, the front fork mounting hole 1 is used for installation and connection with the front fork frame; the seat mounting hole 2 is used for installing the bicycle seat; the rear fork mounting hole 3 is used for installation and connection of the rear fork frame; the motor mounting slot 4 is used for installation and connection of the motor module; the battery mounting slot 5 is used for installation of the battery module; the first shock absorber mounting hole 6 is used for installation of the first shock absorber; the second shock absorber mounting hole 7 is used for installation of the second shock absorber.

[0107] The technical principles of the present invention have been described above in conjunction with specific embodiments. These descriptions are intended solely to illustrate the principles of the present invention and are not to be construed in any way as limiting the scope of protection of the present invention. Based on the explanations herein, those skilled in the art will be able to devise other specific embodiments of the present invention without inventive effort, and such embodiments will fall within the scope of protection of the present invention.

Claims

1. A carbon fiber bicycle processing method, characterized in that: Processing bicycle front fork assemblies, bicycle rear fork assemblies and bicycle frame assemblies respectively; Assembling a bicycle front fork assembly and a bicycle rear fork assembly to two ends of the bicycle frame assembly to obtain a finished carbon fiber bicycle; Wherein, the bicycle frame assembly comprises: a frame shell and a frame accessory module; The frame accessory module is assembled on the frame shell; The processing method of the frame shell comprises the following steps: S1, pre-treating the frame mold to obtain a pre-treated frame mold; S2. Place the frame preform into the frame mold and cover the mold; the frame preform is a multi-layer carbon fiber sheet layer attached to the outer layer of the inner mold core; the inner mold core can be pneumatically shaped and is composed of resin and silicone; S3, closing the frame mold with the completed cover mold; S4, blowing air into the inner mold core of the closed frame mold, attaching carbon fiber sheets, and then hot pressing to obtain a mold with a molded product; S5. Cooling the mold with the molded product and then opening the mold to remove the molded frame shell product; S6. Repair and inspect the finished frame shell products; The invention also includes: releasing a portion of the gas before the inner mold core is placed into the hot pressing mold to make it easier for the preform to be placed into the mold; The space inside the battery box of the vehicle frame is composed of a movable block structure. The problem of undercuts formed inside the prefabricated parts is solved by combining multiple sets of movable blocks and prefabricating the movable blocks into the interior. First install the movable blocks with protrusions on both sides, and then insert the middle movable block into the movable block by setting it in conjunction with the wedge-shaped inclined surface on both sides; After closing the mold, the inner film core is inflated for the second time to make the preform in the mold full; When the frame mold in step S1 is a newly used mold, the following steps are further included: Heat the frame mold to 130-150℃; Blow away debris from the heated frame mold, and then apply release agent inside the frame mold; When the frame mold is a new mold in step S1, the following steps are also included: Wipe off the oil stains on the frame mold; Brush the film-washing agent on the frame mold; Apply release agent to the frame mold; Clean and dry the frame mold; Cool or heat the frame mold to 40-60℃; Blow away debris from the heated frame mold, and then apply release agent inside the frame mold; When the frame mold has not been used for more than one week in step S1, the following steps are further included: Brush the film-washing agent on the frame mold; Apply release agent to the frame mold; Clean and dry the frame mold; Cool or heat the frame mold to 40-60℃; The heated frame mold is blown away to remove debris, and then a release agent is applied inside the frame mold.

2. The method according to claim 1, characterized in that The step S4 further includes: placing a positioning pin on the frame mold that has undergone the mold clamping process, and then pushing the frame mold onto a pallet on the forming table; The frame mold is connected to the air duct and the inner mold core inside the frame mold is inflated for hot pressing molding.

3. The method according to claim 2, characterized in that The step S5 further includes: unplugging the air pipe, pulling out the frame mold, and pushing the frame mold to a cold press table for cooling; After cooling is completed, the frame mold is pulled down from the cold press table and the mold is ready to be opened to take out the molded frame shell product.

4. The method according to claim 3, characterized in that The step S6 further includes: inspecting the appearance of the frame shell product, wherein the technician finally confirms the appearance of the molded body and immediately corrects any abnormalities; The confirmed or improved frame shell products will be sent to QC for inspection.

5. The method according to claim 1, wherein The bicycle front fork assembly comprises: a front fork frame, a front wheel unit and a steering frame unit; The front fork frame is connected to the front end of the frame shell; The front wheel unit and the bogie unit are respectively mounted on the lower portion and the upper portion of the front fork frame.

6. The method according to claim 1, wherein The bicycle rear fork assembly comprises: a rear fork frame, a transmission unit and a rear wheel unit; The rear fork frame is connected to the rear end of the frame shell; The transmission unit and the rear wheel unit are both arranged on the rear fork frame; The transmission unit is in transmission connection with the rear wheel unit.

7. The method according to claim 6, characterized in that The frame accessory module includes: an electronic control module, a battery module, a motor module and a seat module; The electronic control module, the battery module, the motor module and the seat module are all arranged on the frame shell; The electric control module is respectively controlled and connected with the battery module and the motor module; The battery module is connected to the motor module for power supply; The motor module is drivingly connected to the transmission unit.

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