A processing technology of a light-weight solid closed wheel

Abstract

The application relates to the technical field of bicycle wheel rim, and relates to a processing technology of a light-weight solid closed wheel, which comprises the following steps: S1: processing an outer carbon mold groove part in a ring shape; the inner wall surface of the outer carbon mold groove part is a circular ring belt; S2: processing an inner filling buffer; the inner filling buffer is in a circular plate shape; S3: placing the inner filling buffer into the area formed by the inner wall surface of the outer carbon mold groove part, so that the outer wall surface of the inner filling buffer is completely attached to the inner wall surface of the outer carbon mold groove part, and a wheel rim main body is formed; and S4: coating the outer surface of the wheel rim main body with carbon yarn, and then placing the wheel rim main body into a mold for forming. The processing technology of the light-weight solid closed wheel is ingeniously designed; through the processing and combination of the inner filling buffer and the outer carbon mold groove part, the overall strength is sufficient, and the inner filling buffer can effectively play a buffering role.

Description

Technical Field

[0001] This invention relates to the field of bicycle wheel technology, specifically to a manufacturing process for a lightweight solid enclosed wheel. Background Technology

[0002] To reduce wind resistance, many racing bicycles now use closed-rim wheels. At high speeds, closed-rim wheels have better aerodynamic performance and lower wind resistance than high-rim wheelsets from all wind directions, which is beneficial for increasing speed.

[0003] The current traditional process for closed wheels is as follows: The interior of the closed wheel is hollow, and the outer layer is formed directly by multiple layers of carbon yarn. This type of closed wheel is not only very heavy, but also has no cushioning when passing obstacles on the ground during riding because of its hollow structure. On the one hand, it has poor shock absorption and insufficient riding comfort, and on the other hand, it will also lead to a very short overall lifespan of the wheel rim.

[0004] In view of this, the applicant has invented a manufacturing process for a lightweight solid enclosed wheel that is ingeniously designed, has a stable overall structure, and can effectively provide cushioning. Summary of the Invention

[0005] The purpose of this invention is to provide a manufacturing process for a lightweight solid enclosed wheel to solve the problems mentioned in the background art.

[0006] To achieve the above objectives, the present invention provides the following technical solution: A manufacturing process for a lightweight solid enclosed wheel includes the following steps: S1: The outer carbon tire groove is processed and formed into a ring shape, and the inner wall surface of the outer carbon tire groove is a circular band; S2: Process the inner filling buffer material, which is in the shape of a circular plate; S3: Place the inner filling buffer material into the area formed by the inner wall of the outer carbon tire groove, so that the outer wall of the inner filling buffer material is completely attached to the inner wall of the outer carbon tire groove to form the wheel rim body; S4. The outer surface of the wheel rim body is covered with carbon yarn and then placed into a mold for molding.

[0007] As a further improvement, in step S1, the inner wall surface of the outer carbon tire groove is roughened and then coated with adhesive.

[0008] As a further improvement, between steps S2 and S3, step S21 is further included: covering the outer surface of the inner filling buffer with an ultrathin glass sheet.

[0009] As a further improvement, in step S2, the filling buffer is PMI material.

[0010] As a further improvement, the first connecting piece is attached to both sides of the inner filling buffer, the first connecting piece is in the shape of a ring, and the first connecting piece is a glass slide.

[0011] As a further improvement, between steps S3 and S4, step S32 is further included: attaching a second connecting piece between the tire groove portion of the outer carbon tire groove and the side of the inner filling buffer.

[0012] As a further improvement, the second connecting piece is attached to both sides of the inner filling buffer. The second connecting piece extends outward from the outer edge of the inner filling buffer to the outer edge of the outer carbon tire groove, and then bends inward to extend to the middle of the tire groove of the outer carbon tire groove. The second connecting piece is carbon yarn.

[0013] As a further improvement, the outer carbon tire groove is made of carbon yarn, and its heating temperature range is 140 degrees to 160 degrees, and the heating time range is 15 minutes to 30 minutes.

[0014] As a further improvement, in step S4, the outer surface of the wheel rim body is covered with carbon yarn to form an outer sealing plate, wherein the outer sealing plate includes a rigid layer, a torsion layer and a reinforcing layer of the carbon yarn.

[0015] Compared with the prior art, the beneficial effects of the present invention are: 1. The manufacturing process of this lightweight solid enclosed wheel involves machining the inner wall structure of the outer carbon tire groove with a circular belt, combined with a circular plate-shaped inner filler material fully filling the area formed by the inner wall surface. This ensures that the outer wall surface of the inner filler material is in full and stable contact with the inner wall surface of the outer carbon tire groove. On the one hand, the inner filler material acts as a shock absorber for the outer carbon tire groove, thus cushioning the impact on the tire bead fixed to the outer carbon tire groove. On the other hand, the regular surface contact greatly increases the internal strength. Compared with traditional multi-layer carbon yarn or other conventional methods such as filling irregular cushioning materials, the overall weight is much lighter, only about 1.12 kg. The body structure is simple and ingenious in design, and the functions are easy to implement. Attached Figure Description

[0016] Figure 1 is a flowchart of the manufacturing process of a lightweight solid enclosed wheel according to the present invention; Figure 2 is a schematic diagram of the structure of the closed wheel in the processing technology of a lightweight solid closed wheel according to the present invention; Figure 3 is an exploded schematic diagram of the closed wheel in the processing technology of a lightweight solid closed wheel according to the present invention; Figure 4 is a cross-sectional view of the closed wheel along the center position in the processing technology of a lightweight solid closed wheel of the present invention.

[0017] In the diagram: 10, outer carbon tire groove; 20, inner cushioning material; 30, outer sealing plate; 40, connecting piece; 41. First connecting piece; 42. Second connecting piece. Detailed Implementation

[0018] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0019] In the description of this invention, it should be understood that the terms "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.

[0020] In the description of this patent, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," "linking," and "setting" should be interpreted broadly. For example, they can refer to a fixed connection or setting, a detachable connection or setting, or an integral connection or setting. Those skilled in the art can understand the specific meaning of the above terms in this patent according to the specific circumstances.

[0021] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or... This implies relative importance or implicitly specifies the number of technical features being indicated. Therefore, it defines "the first". The features referred to as "a" and "a second" may explicitly or implicitly include one or more of those features. In the description of this invention, "a number" means two or more, unless otherwise explicitly specified.

[0022] Please refer to Figures 1 to 4. A manufacturing process for a lightweight solid enclosed wheel includes the following steps: S1: The outer carbon tire groove 10 is processed and formed into a ring shape. The outer wall surface of the outer carbon tire groove 10 is provided with a tire groove for installing a tire. The inner wall surface of the outer carbon tire groove 10 is a circular ring. The overall weight of the outer carbon tire groove 10 is about 240 grams. S2: Process the inner filling buffer 20, the inner filling buffer 20 is in the shape of a circular plate, and the weight of the inner filling buffer 20 is about 300 grams; S3: Place the inner filling buffer 20 into the area formed by the inner wall of the outer carbon tire groove 10, so that the outer wall of the inner filling buffer 20 is completely attached to the inner wall of the outer carbon tire groove 10 to form the wheel rim body; S4: The outer sealing plate 30 of the closed wheel is formed by covering the outer surface of the wheel rim body with carbon yarn, and then it is placed into a conventional carbon fiber mold for molding. The total weight of the carbon yarn is about 370 grams. S5: After fine painting, the hub is glued (not shown in the picture). The outer surface is treated with conventional processes such as roughening, sanding, touch-up painting, baking paint and labeling to achieve an aesthetic decoration effect. The hub weighs about 210 grams.

[0023] The enclosed wheel, through the inner wall structure of the outer carbon tire groove 10 of the circular belt, combined with the circular plate-shaped inner filling buffer 20 fully filling the area formed by the inner wall surface, ensures that the outer wall surface of the inner filling buffer 20 is in full and stable contact with the inner wall surface of the outer carbon tire groove 10. On the one hand, the inner filling buffer 20 plays a role in shock absorption and cushioning of the outer carbon tire groove 10, thereby buffering and absorbing the impact on the tire bead fixed outside the outer carbon tire groove 10. On the other hand, the regular surface contact greatly increases the internal strength. Compared with traditional multi-layer carbon yarn or other conventional methods such as filling irregular cushioning materials, the overall weight is much lighter, with an overall weight of only about 1.12 kg. Furthermore, the outer carbon tire groove 10 and the inner filling buffer 20 have regular shapes and no excessive curved surfaces, with a simple and ingenious structural design that is easy to manufacture.

[0024] Furthermore, in step S1, the traditional carbon fiber wheel rim forming process with an internal air bag is first used. After molding, the outer ring air duct is removed and sprayed with yarn. Then, the inner wall surface of the outer carbon tire groove 10 is roughened and then coated with adhesive. Specifically, the adhesive is applied with resin. By combining the roughening process of the inner wall surface with the adhesive application, the bonding strength between the inner wall surface of the outer carbon tire groove 10 and the outer wall surface of the inner filling buffer 20 can be further improved, effectively enhancing the structural stability of the overall closed wheel and ensuring that the two contact surfaces will not fall off or slip.

[0025] Furthermore, between steps S2 and S3, step S21 is further included: covering the outer surface of the inner filling buffer 20 with an ultra-thin glass sheet, the outer surface of which can be fully bonded to the inner wall of the roughened outer carbon tire groove 10 under the adhesive action of resin.

[0026] Furthermore, in step S2, the inner filling buffer 20 is made of PMI material, which is machined by CNC to ensure that its thickness tolerance is between +1.2 and +1.5 mm, and its diameter tolerance is controlled between +0.1 mm and +0.15 mm. By increasing the thickness and diameter of the inner filling buffer 20 in advance and compressing it during the final mold forming process, the overall strength after molding is higher and the final thickness and diameter are more accurate. Through precise dimensional control, it is ensured that the final thickness and diameter are flush with the relevant edges of the outer carbon tire groove 10 and in full contact. By using PMI, a lightweight, closed-cell rigid foam plastic, the overall closed wheel is lightweight, and the filling buffer can provide sufficient support strength for the outer carbon tire groove 10 through full contact with the inner wall of the outer carbon tire groove 10. In addition, the material properties of the foam plastic also have a certain degree of softness and resilience, which provides better cushioning for the closed wheel as a whole.

[0027] Please refer to Figure 3. Between steps S3 and S4, a further step S31 is included: a first connecting piece 41 is attached between the side of the outer carbon tire groove 10 and the outer ring of the inner filling buffer 20. Specifically, in this embodiment, a first connecting piece 41 is attached to both sides of the inner filling buffer 20. The first connecting piece 41 is circular and is circumferentially attached along the gap between the inner filling buffer 20 and the outer carbon tire groove 10. The first connecting piece 41 is a glass plate, and the length of the first connecting piece 41 ranges from 1.7 to 2.3 m, and the width of the first connecting piece 41 ranges from 1.5 to 2.5 cm. Preferably, the length of the first connecting piece 41 is 2 m and the width is 2 cm.

[0028] The outer carbon tire groove 10 and the inner filling buffer 20 are pre-connected and pre-positioned by a small, easily attachable annular first connecting piece 41. At the same time, the glass sheet material makes it easy to lay the second connecting piece 42 and the outer carbon yarn, thus achieving a stable connection between the outer carbon tire groove 10 and the inner filling buffer 20, and further avoiding the problem of insufficient support strength caused by the separation of the two during tire rolling.

[0029] Furthermore, between steps S3 and S4, step S32 is further included: a second connecting piece 42 is attached between the tire groove portion of the outer carbon tire groove component 10 and the outer ring portion of the inner filling buffer 20. Specifically, a second connecting piece 42 is attached to both sides of the inner filling buffer 20. The second connecting piece 42 extends outward from the outer edge of the inner filling buffer 20 to the outer edge of the outer carbon tire groove component 10, and then bends inward and extends to the middle of the tire groove portion of the outer carbon tire groove component 10. The second connecting piece is carbon yarn.

[0030] The outer carbon tire groove 10 is reverse-wrapped by the second connecting piece 42 that fits in a full circle. This generates an inward pulling force on the outer carbon tire groove 10, thereby improving the connection strength between the outer carbon tire groove 10 and the inner filling buffer 20 and ensuring the overall structure is dense.

[0031] Furthermore, the second connecting piece 42 is formed by cross-bonding of 45-degree carbon yarn and 135-degree carbon yarn to improve the uniformity of the bonding strength between the parts and reduce the risk of the internal parts falling off or breaking under external impacts other than radial directions. The width ranges from 35mm to 45mm, the length ranges from 1.5m to 2.5m, preferably 40mm wide, 2m long, and 0.075mm thick. The second connecting piece 42, which is bonded in a circumferential manner, ensures the wrapping strength on the one hand, and provides a smooth surface for the carbon yarn that is subsequently laid to form the outer side of the closed wheel on the other hand.

[0032] Please refer to Figure 4. The material of the outer carbon tire groove 10 is carbon yarn. Its heating temperature range is 140 degrees to 160 degrees, and the heating time range is 15 minutes to 30 minutes. By controlling its molding temperature and molding time, the outer carbon tire groove 10 can achieve pre-forming, that is, its hardness is about half of that of normal fully formed. This facilitates easy bonding during the secondary fully formed process when it is combined with the inner filling buffer 20, the outer sealing plate 30, and the connecting piece 40, and ensures sufficient strength so that it does not collapse under external force.

[0033] The outer carbon tire groove component 10 can be attached using conventional carbon yarn, such as the T700 carbon yarn from Qingdao Dongaike Composite Materials Co., Ltd., with a groove thickness of 0.8mm and an inner ring thickness of 0.15mm. For further improvement in overall rigidity and flexibility, T1000 carbon yarn can be used to ensure overall rigidity, while nylon filaments can be added to enhance flexibility, preventing breakage during riding due to excessive rigidity. The carbon yarn of the outer carbon tire groove component 10 has an inner ring diameter tolerance of less than 0.1mm, a heating temperature range of 140°C to 160°C, and a heating time range of 15 minutes to 30 minutes.

[0034] In addition, in step S4, an outer sealing plate is formed by covering the outer surface of the wheel rim body with carbon yarn. 30. The outer sealing plate 30 includes a rigid layer, a torsion layer, and a reinforcing layer. The rigid layer is a 90-degree yarn layer used to improve positive rigidity, the torsion layer is a 70-degree yarn layer used to improve the torsional force required during turning, and the reinforcing layer is used to supplement and improve the overall strength. Similarly, the carbon yarn mentioned above can all be made of T700 carbon yarn. After adding the ultra-thin glass cloth, the first connecting piece 41, and the second connecting piece 42 to the multi-layer carbon yarn structure, the overall weight is controlled to be about 370 grams. The whole structure is placed in a conventional carbon fiber molding mold, and the final overall molding is completed by controlling the heating temperature range of 140 degrees to 160 degrees and the heating time range of 30 minutes to 50 minutes.

[0035] The foregoing has shown and described the basic principles, main features, and advantages of the present invention. Those skilled in the art should understand that the present invention is not limited to the above embodiments. The embodiments and descriptions in the specification are merely preferred examples and are not intended to limit the invention. Various changes and modifications can be made to the invention without departing from its spirit and scope, and all such changes and modifications fall within the scope of the present invention as claimed. The scope of protection of the present invention is defined by the appended claims and their equivalents.

Claims

1. A manufacturing process for a lightweight solid enclosed wheel, characterized in that, Includes the following steps: S1: The outer carbon tire groove (10) is processed and formed into an annular shape, and the inner wall surface of the outer carbon tire groove (10) is a circular band; S2: Process the inner filling buffer (20), wherein the inner filling buffer (20) is in the shape of a circular plate; S3: Place the inner filling buffer (20) into the area formed by the inner wall of the outer carbon tire groove (10), so that the outer wall of the inner filling buffer (20) is completely attached to the inner wall of the outer carbon tire groove (10) to form the wheel rim body; S31: A first connecting piece (41) is attached between the side of the outer carbon tire groove (10) and the outer ring of the inner filling buffer (20), wherein the first connecting piece (41) is attached to both sides of the inner filling buffer (20), the first connecting piece (41) is in the shape of a ring and is attached to the entire ring around the gap between the inner filling buffer (20) and the outer carbon tire groove (10), and the first connecting piece (41) is a glass slide; S32: A second connecting piece (42) is attached between the tire groove of the outer carbon tire groove (10) and the side of the inner filling buffer (20). The second connecting piece (42) is attached to both sides of the inner filling buffer (20). The second connecting piece (42) extends outward from the outer edge of the inner filling buffer (20) to the outer edge of the outer carbon tire groove (10), and then bends inward to extend to the middle of the tire groove of the outer carbon tire groove (10). The second connecting piece (42) is carbon yarn. S4: The outer surface of the wheel rim body is covered with carbon yarn and then placed into a mold for molding.

2. The processing technology of the lightweight solid enclosed wheel according to claim 1, characterized in that: In step S1, the inner wall surface of the outer carbon tire groove (10) is roughened and then coated with adhesive.

3. The processing technology of the lightweight solid enclosed wheel according to claim 2, characterized in that, Between steps S2 and S3, step S21 is further included: covering the outer surface of the inner filling buffer (20) with an ultrathin glass sheet.

4. The processing technology of the lightweight solid enclosed wheel according to claim 1, characterized in that: In step S2, the inner filling buffer (20) is PMI material.

5. The processing technology of the lightweight solid enclosed wheel according to claim 1, characterized in that: The outer carbon tire groove (10) is made of carbon yarn, and its heating temperature range is 140 degrees to 160 degrees, and the heating time range is 15 minutes to 30 minutes.

6. The processing technology of the lightweight solid enclosed wheel according to claim 1, characterized in that: In step S4, the outer surface of the wheel rim body is covered with carbon yarn to form an outer sealing plate (30), the outer sealing plate (30) including a rigid layer, a torsion layer and a reinforcing layer.

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