Low-energy-consumption manufacturing process of recoverable acryl carbon fiber rim

Abstract

The invention relates to a low-energy-consumption manufacturing process of a recoverable acrylic carbon fiber rim. A water-soluble body core shaft, a water-soluble open tire type core shaft and a reinforcing piece are prepared, the body core shaft and the open tire type core shaft are coated with dry carbon fibers respectively, then the body core shaft, the open tire type core shaft and the reinforcing piece are coated with the dry carbon fibers to form a whole, the whole is placed in a mold, the mold is closed and vacuumized, and the water-soluble body core shaft, the water-soluble open tire type core shaft and the reinforcing piece are manufactured. Acryl slurry added with a normal-temperature initiator / accelerant is injected into the mold, heating is not needed, high-pressure air is added, standing is carried out for about 20-30 minutes, after polymerization reaction is completed, a carbon fiber rim primary blank is taken out, a plurality of steel wire penetrating holes are drilled, then the carbon fiber rim primary blank is placed in water, and the body mandrel and the opening tire type mandrel are dissolved out, so that the manufacturing process can be completed. The energy is saved, the environment-friendly and recoverable benefits are achieved, the manufacturing process is simple, and the core shaft material dissolved out through warm water can be recycled.

Description

Technical Field

[0001] The invention relates to a carbon fiber wheel rim manufacturing process, and in particular to an energy-saving, environmentally friendly and recyclable acrylic carbon fiber wheel rim low-energy consumption manufacturing process. Background Art

[0002] According to the current process of thermosetting carbon fiber wheel rims, please refer to Figure 5 As shown in the process, carbon fiber prepreg material is used, which is cut and affixed layer by layer to a core shaft, and finally placed in a mold and cured by heating and pressurizing.

[0003] There is also a method of winding carbon fiber, infusing it with resin, and then heating and pressurizing it for curing, such as patent certificate number: TWI716716B. In addition to consuming energy, the clincher core shaft is cut after curing, resulting in fiber discontinuity. The detailed disadvantages are described in "Uncle Sam's Pixnet Blog" APR 06 2019 titled "Analysis of the Structure and Molding of Carbon Fiber Rim CLINCHER".

[0004] In addition, there are also processes for thermoplastic carbon fiber rims in foreign countries. Figure 6 As shown in the process, it also uses polymer thermoplastic prepreg such as PA / CF, PC / CF prepreg, which is gradually formed by hot pressing and high frequency. However, due to the use of polymer thermoplastics, due to its high viscosity, it is not good for carbon fiber impregnation, and due to its high melting point, its molding temperature is higher than that of thermosetting resin, at least higher than 200 degrees C, and a lot of energy and time are consumed between heating and rapid cooling.

[0005] In view of this, the inventor, with many years of experience in manufacturing, developing and designing related products, has finally obtained a practical invention after detailed design and careful evaluation for the above-mentioned goals. Summary of the invention

[0006] The technical problem to be solved by the present invention is to provide a low-energy consumption process for a recyclable acrylic carbon fiber wheel rim in view of the above-mentioned deficiencies in the prior art, including:

[0007] A water-soluble body mandrel is prepared, the body mandrel is a thin shell air bag, and at least one dry carbon fiber sheet is continuously wound or covered on the body mandrel to form a first embryo; a water-soluble open tire mandrel is prepared, the open tire mandrel is a solid mandrel, and at least one dry carbon fiber sheet is continuously wound or covered on the open tire mandrel to form a second embryo;

[0008] A reinforcing piece is prepared and arranged in a ring on the inner side of the first preform; the first preform is arranged in a ring on the inner side of the second preform, and at least one dry carbon fiber sheet is continuously wound or covered on the first preform, the second preform and the reinforcing piece to form a rim preform;

[0009] The wheel rim is preformed in a mold, and after the mold is closed, it is vacuumed and poured into an acrylic slurry that has been activated by an initiator / accelerator and reacts at room temperature. It does not need to be heated and is pressurized and left to stand. After the reaction at room temperature, the mold is opened and taken out, and a plurality of steel wire holes are drilled and then immersed in water to dissolve the main body core shaft and the open tire core shaft, so that the carbon fiber wheel rim is completed.

[0010] Preferably, the main body core shaft is a thin shell air bag made of PVA material, shaped like an annular wheel frame, and the open tire type core shaft is a solid core shaft extruded or injection molded by PVA material, shaped like an open annular wheel rim groove.

[0011] Preferably, the dry carbon fiber sheet is at least any one of the carbon fiber structures including needle-rolled dry carbon fiber, unidirectional dry carbon fiber bonded into a sheet with an adhesive, unidirectional dry carbon fiber bonded into a sheet with a low-melting point yarn, carbon fiber woven cloth, round woven belt or sleeve, and carbon fiber non-woven cloth.

[0012] Preferably, the reinforcement ring is an annular carbon fiber reinforcement ring formed by any method such as winding, molding or pre-forming.

[0013] Preferably, the activated room temperature reactive acrylic slurry comprises a slurry composed of acrylic monomers, oligomers, recycled acrylic powder particles, UV resistant agents, surfactants, modifying additives and other low viscosity liquids.

[0014] Preferably, the room temperature reactive peroxide initiator is one of AIBN, BPO, DCP, methyl ethyl ketone peroxide (MEKP), cyclohexanone peroxide (CYHP, CHPO), cumene hydroperoxide (CHP), acetylacetone peroxide (AAP), dibenzoyl peroxide (BPO), etc., and the room temperature accelerator is a DMA accelerator, such as cobalt naphthenate, cobalt isooctanoate, zinc isooctanoate, N,N-dimethylaniline, N,N-diethylaniline, vanadium phosphate, etc.

[0015] Preferably, the acrylic slurry forms a high molecular weight thermoplastic acrylic polymer (Mw>250000, Mn>65000) after reacting at room temperature.

[0016] Compared with the efficacy of the prior art: the process of the present invention does not require heating during molding, which saves energy and is environmentally friendly. The process is simple and cost-effective. After the carbon fiber rim is formed, the main body mandrel and the open tire mandrel dissolved by warm water are both recyclable and reusable. It is a low-carbon production feature, which solves the problems of energy consumption, time consumption, and labor consumption in the production of traditional carbon fiber rims, and also solves the problems of high temperature, high viscosity and poor impregnation required for current thermoplastic composites. It is a low-energy, environmentally friendly and recyclable advanced process. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] Figure 1 The figure is a block diagram of the carbon fiber wheel rim manufacturing process of the present invention.

[0018] Figure 2 It is a schematic diagram of the wheel rim preforming step of the present invention.

[0019] Figure 3 It is a schematic diagram of the wheel rim preform mold pressurizing and pouring acrylic slurry according to the present invention.

[0020] Figure 4 It is a schematic diagram of drilling holes in the carbon fiber wheel rim embryo of the present invention and soaking it in warm water to dissolve the mandrel to complete the carbon fiber wheel rim.

[0021] Figure 5 The figure is a block diagram of the manufacturing process of the existing thermosetting carbon fiber wheel rim.

[0022] Figure 6 The figure is a block diagram of the manufacturing process of the existing thermoplastic carbon fiber wheel rim.

[0023] Explanation of symbols:

[0024] [The present invention]

[0025] 10:Body mandrel

[0026] 11: Dry carbon fiber sheet

[0027] 100: The first embryo

[0028] 20: Open tire mandrel

[0029] 21: Dry carbon fiber sheet

[0030] 200: Second embryo

[0031] 30: Reinforcement

[0032] 40: Dry carbon fiber sheet

[0033] 400: Rim preform

[0034] 410:Mold

[0035] 420:Acrylic slurry

[0036] 440: Carbon fiber wheel rim blank

[0037] 441:Wire perforation

[0038] 500: Carbon fiber rims DETAILED DESCRIPTION

[0039] In order to further understand and appreciate the purpose, features and effects of the present invention, please refer to the following [Brief Description of the Drawings] for details:

[0040] Please Figures 1 to 4 As shown, a low-energy consumption process for recyclable acrylic carbon fiber wheel rims includes the following steps:

[0041] A water-soluble body core shaft 10 is prepared. The body core shaft 10 is made of a thin shell air bag made of PVA material and is shaped like a ring-shaped wheel frame. At least one dry carbon fiber sheet 11 is continuously wrapped around the body core shaft 10. For example, at least one multi-axial fabric is used to wrap the dry carbon fiber sheet 11 with two layers of (+45, -45 degrees) angles. Fine cotton yarn or acrylic glue such as LOTADEL AX8090 is then wrapped and fixed on the body core shaft 10 to form a first embryo 100.

[0042] A water-soluble open tire mandrel 20 is prepared. The open tire mandrel 20 is a solid mandrel made of PVA material by extrusion or injection molding, and is shaped like an open annular rim. At least one dry carbon fiber sheet 21 is continuously wound or covered on the open tire mandrel 20, for example, the dry carbon fiber sheet 21 with two layers (+45, -45 degrees) angles in at least one multi-axial fabric is wrapped, and then fine cotton yarn is wound or glued to fix on the open tire mandrel 20 to form a second primary embryo 200;

[0043] A reinforcing member 30 is provided, wherein the reinforcing ring 30 is an annular carbon fiber reinforcing ring formed by winding, pultrusion, molding or other pre-forming methods, and the reinforcing member 30 is arranged on the inner side of the first preform 100;

[0044] The first preform 100 is placed inside the second preform 200, and at least one dry carbon fiber sheet 40 is continuously wrapped around the first preform 100, the second preform 200 and the reinforcing member 30, for example, at least one multi-axial fabric with 4 layers of dry carbon fiber sheets (0, +45, -45 and 90 degrees) is used for wrapping, and then the three are fixed by winding with fine cotton yarn or glue to form a rim preform 400;

[0045] The wheel rim preform 400 is placed in a mold 410, and after the mold is closed, vacuum is drawn and an acrylic slurry 420 that has been activated and reacted at room temperature is poured. The activated acrylic slurry 420 that has been activated and reacted at room temperature includes a slurry composed of low-viscosity liquids and powders such as acrylic monomers (such as MMA, EMA, etc.), oligomers, recycled acrylic powder, anti-ultraviolet agents, surfactants, modification additives, and nanomaterials (such as nano TiO2. Clay, graphene, etc.), and a room-temperature reactive peroxide initiator and a room-temperature accelerator are added. The room-temperature reactive peroxide initiator is a mixed initiator such as AIBN, BPO, DCP, methyl ethyl ketone peroxide (MEKP), cyclohexanone peroxide (CYHP, CHPO), cumene hydroperoxide (CHP), acetylacetone peroxide (AAP), dibenzoyl peroxide (BPO), etc. The room temperature accelerator is a DMA accelerator, such as cobalt naphthenate, cobalt isooctanoate, zinc isooctanoate, N,N-dimethylaniline, N,N-diethylaniline, vanadium phosphate, etc., wherein the vacuum operation allows the acrylic slurry 420 to fully penetrate into the dry carbon fiber sheets 11, 21, 30 to avoid residual bubbles, which helps to improve the toughness of the dry carbon fiber sheets 11, 21, 40. Then, the acrylic slurry 420 is poured and the pouring time is controlled to be less than the reaction start exothermic time or gelation time. After the pouring is completed, no heating is required. High-pressure gas (>5kg / cm2) is injected into the main body core shaft 10 and left at room temperature for 20 to 30 minutes for polymerization reaction. The acrylic slurry 420 forms a thermoplastic high molecular weight acrylic carbon fiber composite after the room temperature reaction, thereby forming a carbon fiber wheel rim embryo 440;

[0046] Then, the carbon fiber wheel rim embryo 440 after the room temperature reaction is taken out from the mold 410, and then the carbon fiber wheel rim embryo 440 is penetrated from the inside to the outside through the reinforcement 30, the first embryo 100 and the second embryo 200 to drill a plurality of steel wire through holes 441 for assembling steel wires, and then the carbon fiber wheel rim embryo 440 is immersed in warm water to dissolve the main body core shaft 10 and the open tire core shaft 20 made of PVA material, so as to complete a carbon fiber wheel rim 500.

[0047] The dry carbon fiber sheets 11, 21, 40 described in the above process are at least any one of the above carbon fiber structures, such as needle-rolled dry carbon fiber, unidirectional dry carbon fiber combined into sheets with adhesive, unidirectional dry carbon fiber combined into sheets with low-melting point yarn, carbon fiber woven cloth, round woven belt or sleeve and carbon fiber non-woven cloth.

[0048] Through the structure of the above-mentioned specific embodiment, the following benefits can be obtained: the process of the present invention does not require heating during molding, which saves energy and is environmentally friendly. The process is simple and cost-effective. After the carbon fiber rim is formed, the main body core shaft and the open tire core shaft dissolved by warm water are both recyclable and reusable. It is a low-carbon production feature, which solves the problems of energy consumption, time consumption, and labor consumption in the production of traditional carbon fiber rims, and also solves the problems of high temperature, high viscosity and poor impregnation required for current thermoplastic composites. It is a low-energy, environmentally friendly and recyclable advanced process.

[0049] The above description is only a preferred embodiment of the present invention and should not be used to limit the scope of the present invention. That is, all equivalent changes and modifications made according to the scope of the patent application of the present invention should still fall within the scope covered by the patent of the present invention.

Claims

1. A low energy consumption process for recyclable acrylic carbon fiber wheel rims, characterized in that: include: A water-soluble main body mandrel is prepared, the main body mandrel is a thin shell air bag, and at least one dry carbon fiber sheet is continuously wrapped around the main body mandrel to form a first embryo; A water-soluble open tire mandrel is prepared, wherein the open tire mandrel is a solid mandrel, and at least one dry carbon fiber sheet is continuously wrapped around the open tire mandrel to form a second embryo; A reinforcing member is provided, which is disposed around the inner side of the first embryo; The first preform is placed inside the second preform, and at least one dry carbon fiber sheet is continuously wrapped around the first preform, the second preform and the reinforcing member to form a rim preform; The wheel rim preform is placed in a mold, and after the mold is closed, vacuum is drawn and an acrylic slurry that has been activated and reacts at room temperature is poured in. It is not necessary to heat and is pressurized and allowed to stand. After the reaction at room temperature, the mold is opened and taken out, and then at least one steel wire hole is drilled and immersed in water to dissolve the main body core shaft and the open tire core shaft, so that the carbon fiber wheel rim is completed.

2. The low energy consumption process for recyclable acrylic carbon fiber wheel rim according to claim 1, characterized in that: The main body core shaft is a thin shell air bag made of PVA material, and its shape is like an annular wheel frame. The open tire type core shaft is a solid core shaft extruded and injection molded by PVA material, and its shape is like an open annular wheel rim groove.

3. The low energy consumption process for recyclable acrylic carbon fiber wheel rim according to claim 1, characterized in that: The dry carbon fiber sheet is at least one of the carbon fiber structures including needle-rolled dry carbon fiber, unidirectional dry carbon fiber bonded into a sheet with an adhesive, unidirectional dry carbon fiber bonded into a sheet with a low-melting-point yarn, carbon fiber woven cloth, round woven belt or sleeve, and carbon fiber non-woven cloth.

4. The low energy consumption process for recyclable acrylic carbon fiber wheel rim according to claim 1, characterized in that: The reinforcing ring is an annular carbon fiber reinforcing ring formed by any method such as winding, pultrusion, molding and pre-forming.

5. The low energy consumption process for recyclable acrylic carbon fiber wheel rim according to claim 1, characterized in that: The activated acrylic slurry for room temperature reaction includes acrylic monomers, oligomers, recycled acrylic powder particles, UV inhibitors, surfactants, modification additives, nanomaterials and other low viscosity liquids and powder particles, and a room temperature reactive peroxide initiator and room temperature accelerator.

6. The low energy consumption process for recyclable acrylic carbon fiber wheel rim as claimed in claim 5, characterized in that: The room temperature reactive peroxide initiator is at least one of AIBN, BPO, DCP, methyl ethyl ketone peroxide (MEKP), cyclohexanone peroxide (CYHP, CHPO), cumene hydroperoxide (CHP), acetylacetone peroxide (AAP), dibenzoyl peroxide (BPO), etc., and the room temperature accelerator is a DMA accelerator, such as cobalt naphthenate, cobalt isooctanoate, zinc isooctanoate, N,N-dimethylaniline, N,N-diethylaniline, vanadium phosphate, etc.

7. The low energy consumption process for recyclable acrylic carbon fiber wheel rim according to claim 1, characterized in that: The acrylic slurry forms a thermoplastic high molecular weight acrylic carbon fiber composite after reacting at room temperature.

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