A handlebar production process

Abstract

The present application relates to handle manufacturing technical field, specifically disclose a kind of lightweight intelligent vehicle handle production process, the process includes four major procedures of composite laminating forming, cavity processing and sensor integration, surface treatment and intelligent assembly and test.Innovation uses carbon fiber prepreg and magnesium-aluminum alloy foil alternative layup structure, by 0 ° / 90 ° / 45 ° cross arrangement and vacuum hot-pressing solidification form high-strength matrix;Laser cutting trapezoidal cavity in matrix, embedded function is realized by integrating flexible sensor, heating element and filling silica gel;Surface is through plasma cleaning combination nano ceramic coating and laser engraving non-slip line to improve durability;Final assembly bluetooth module and through vibration fatigue and function calibration ensure reliability, the present application realizes lightweight, high bending strength and intelligent function integration, 90% VOC emissions are reduced using low-temperature plasma and nano coating process, applicable to motorcycle, electric vehicle and other traffic tool handle manufacturing.

Description

Technical Field

[0001] This invention relates to the field of handlebar technology, and more specifically to a handlebar manufacturing process. Background Technology

[0002] Traditional motorcycle handlebars are mostly made of metal (such as aluminum alloy) and formed by casting or machining, resulting in problems such as heavy weight, limited functionality, and easy surface corrosion. Existing technologies have attempted to improve this by introducing composite materials or adding heating functions, but the following drawbacks remain: ① Lightweight materials and structural design are not fully integrated, making it difficult to balance strength and weight reduction; ② External sensors or electronic components affect aesthetics and are susceptible to environmental damage; ③ The production process is energy-intensive and lacks environmental friendliness. Summary of the Invention

[0003] In view of the shortcomings of the existing technology, the present invention provides a handlebar manufacturing process to solve the defects of traditional processes in terms of weight, function and environmental protection.

[0004] To achieve the above objectives, the present invention provides the following technical solution: A handlebar manufacturing process includes the following steps: S1. Composite lamination molding: The material is pretreated to obtain carbon fiber prepreg and magnesium-aluminum alloy foil. Then, the carbon fiber prepreg and magnesium-aluminum alloy foil are alternately laid and finally vacuum hot-pressed for curing. S1.1 Material pretreatment: The carbon fiber prepreg is thawed at room temperature for 24 hours to remove the surface protective film. At the same time, the magnesium-aluminum plate is subjected to surface alkaline washing and sandblasting to increase the interlayer bonding force and make magnesium-aluminum alloy foil. S1.2 Alternating Lay-up: Carbon fiber prepreg and magnesium-aluminum alloy foil are alternately laid up in the order of "carbon fiber-magnesium-aluminum-carbon fiber", with a total of 6 layers. The lay-up angles are 0° / 90° / 45° and arranged in an alternating pattern to optimize isotropic strength. At the same time, a coupling agent is uniformly coated between each layer during lay-up to prevent delamination. S1.3 Vacuum hot pressing curing: Place the layup into the mold, put it in a vacuum autoclave, evacuate the vacuum, heat it to 150-200℃, pressurize it to 10-12MPa, hold the pressure for 2-3 hours, and then enter the cooling stage, cooling down in a gradient, and naturally cooling to room temperature to form the matrix. S2. Cavity processing and sensor integration: The substrate is laser-cut to form a cavity, where sensors and heating elements are embedded and silicone is injected. S3. Surface treatment: After plasma cleaning of the substrate, a nano-ceramic coating is deposited, followed by laser engraving of anti-slip texture; S4. Intelligent assembly and testing: The Bluetooth module is packaged, followed by vibration fatigue testing and functional calibration.

[0005] Further, step S2 includes: S2.1 Using a laser cutting machine, cut a cavity with a trapezoidal cross-section along the length of the handle base; S2.2 Cut the flexible PCB thin film sensor according to the shape of the holding area, attach it to the inner wall of the cavity, and fix the contacts with conductive silver paste; S2.3 Arrange the heating wire in a serpentine path at the bottom of the cavity, and weld copper wires to both ends for lead-out; S2.4. Inject two-component liquid silicone, vacuum degas, and pour after preheating the mold at 40-60℃. Cure at 60-80℃ for 40 minutes.

[0006] Further, step S3 includes: S3.1. Use radio frequency plasma equipment, introduce argon gas, process for 10 minutes to remove surface organic matter and activate the coating bonding surface; S3.2. A nano-ceramic coating is deposited on the surface of the handle substrate by magnetron sputtering; S3.3. Use an ultraviolet laser to engrave a diamond-shaped grid pattern, and repeat 3 times to ensure the texture is clear.

[0007] Further, step S4 includes: S4.1 Embed the Bluetooth module into the pre-drilled groove at the end of the handle and fill it with epoxy resin; S4.2. Using an electromagnetic vibration table, load according to the vibration spectrum and vibrate continuously for 1×10⁻⁶ seconds. 6 After each cycle, check the structure for cracks and ensure the sensors are functioning properly. S4.3. Calibrate the heating function by applying a 12V voltage, testing the heating curve of the resistance wire, and then making judgments and calibrations. S4.4. Calibrate the sensor by applying 0-100N pressure using a standard press to calibrate the linearity of the sensor output, followed by judgment and calibration.

[0008] Furthermore, the nano-ceramic coating comprises, in sequence, a bottom TiN layer, an intermediate Al2O3 layer, and a surface TiN layer.

[0009] Furthermore, the carbon fiber prepreg uses T700 grade carbon fiber woven fabric, with an epoxy resin content of 35±2% and a single-layer thickness of 0.15mm.

[0010] Compared with the prior art, the beneficial effects of the present invention are: 1. Combining lightweight and high strength: The composite laminate structure reduces weight by more than 30% and increases bending strength by 20% compared to traditional metal handles; It adopts a carbon fiber / magnesium-aluminum alloy composite laminate structure, and achieves local thickening and hollowing weight reduction through optimized design (weight reduction ≥30%, bending strength ≥500MPa). The handle has a pre-embedded cavity that integrates a pressure sensor array (covering more than 90% of the grip area) and a heating resistance wire. The cavity is filled with silicone damping material to absorb vibration. 2. Intelligent and reliable: Built-in sensors monitor riding status in real time, and silicone filling and nano-coating achieve waterproof and shockproof performance; 3. Environmental friendliness: Low-temperature plasma cleaning and nano-coating technology replace highly polluting chemical processes, reducing VOC emissions by 90%; 4. Process efficiency: Integrated molding reduces assembly steps and shortens the production cycle by 40%. Detailed Implementation

[0011] In the description of this invention, it should be noted that the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features. Thus, the use of "first" and "second" to describe a feature may explicitly or implicitly include one or more of that feature. In the description of this invention, "several" or "a number" means two or more, unless otherwise explicitly specified.

[0012] A handlebar manufacturing process includes the following steps: S1. Composite lamination molding: The material is pretreated to obtain carbon fiber prepreg and magnesium-aluminum alloy foil. Then, the carbon fiber prepreg and magnesium-aluminum alloy foil are alternately laid and finally vacuum hot-pressed for curing. S1.1 Material pretreatment: The carbon fiber prepreg is thawed at room temperature (humidity ≤30%) for 24 hours to remove the surface protective film. At the same time, the magnesium-aluminum plate is subjected to surface alkaline washing and sandblasting to increase the interlayer bonding force and make magnesium-aluminum alloy foil. S1.2 Alternating Lay-up: Carbon fiber prepreg and magnesium-aluminum alloy foil are alternately laid up in the order of "carbon fiber-magnesium-aluminum-carbon fiber", with a total of 6 layers. The lay-up angles are 0° / 90° / 45° and arranged in an alternating pattern to optimize isotropic strength. At the same time, a coupling agent is uniformly coated between each layer during lay-up to prevent delamination. S1.3 Vacuum hot pressing curing: Place the layup into the mold, put it in a vacuum autoclave, evacuate the vacuum, heat it to 150-200℃, pressurize it to 10-12MPa, hold the pressure for 2-3 hours, and then enter the cooling stage, cooling down in a gradient, and naturally cooling to room temperature to form the matrix. S2. Cavity processing and sensor integration: The substrate is laser-cut to form a cavity, where sensors and heating elements are embedded and silicone is injected. S3. Surface treatment: After plasma cleaning of the substrate, a nano-ceramic coating is deposited, followed by laser engraving of anti-slip texture; S4. Intelligent assembly and testing: The Bluetooth module is packaged, followed by vibration fatigue testing and functional calibration.

[0013] Preferably, the magnesium-aluminum plate is AZ31B magnesium-aluminum plate with a thickness of 0.5mm. The surface is alkaline washed by soaking in a 10% NaOH solution at 60°C for 5 minutes.

[0014] Preferably, step S2 includes: S2.1 Using a laser cutting machine, cut a cavity with a trapezoidal cross-section along the length of the handle base; S2.2 Cut the flexible PCB thin film sensor according to the shape of the holding area, attach it to the inner wall of the cavity, and fix the contacts with conductive silver paste; S2.3 Arrange the heating wire in a serpentine path at the bottom of the cavity, and weld copper wires to both ends for lead-out; S2.4. Inject two-component liquid silicone, vacuum degas, and pour after preheating the mold at 40-60℃. Cure at 60-80℃ for 40 minutes.

[0015] Preferably, step S3 includes: S3.1. Use radio frequency plasma equipment, introduce argon gas, process for 10 minutes to remove surface organic matter and activate the coating bonding surface; S3.2. A nano-ceramic coating is deposited on the surface of the handle substrate by magnetron sputtering; S3.3. Use an ultraviolet laser to engrave a diamond-shaped grid pattern, and repeat 3 times to ensure the texture is clear.

[0016] Preferably, step S4 includes: S4.1 Embed the Bluetooth module into the pre-drilled groove at the end of the handle and fill it with epoxy resin; S4.2. Using an electromagnetic vibration table, load according to the vibration spectrum and vibrate continuously for 1×10⁻⁶ seconds. 6 After each cycle, the structure is checked for cracks, the sensors are functioning properly, and the structural stability is verified. S4.3. Calibrate the heating function by applying a 12V voltage, testing the heating curve of the resistance wire, and then making judgments and calibrations. S4.4. Calibrate the sensor by applying 0-100N pressure using a standard press to calibrate the linearity of the sensor output, followed by judgment and calibration.

[0017] Preferably, the nano-ceramic coating comprises, in sequence, a bottom TiN layer, an intermediate Al2O3 layer, and a surface TiN layer.

[0018] Preferably, the carbon fiber prepreg is made of T700 grade carbon fiber woven fabric, with an epoxy resin content of 35±2% and a single layer thickness of 0.15mm.

[0019] advantage: 1. Combining lightweight and high strength: The composite laminate structure reduces weight by more than 30% and increases bending strength by 20% compared to traditional metal handles; It adopts a carbon fiber / magnesium-aluminum alloy composite laminate structure, and achieves local thickening and hollowing weight reduction through optimized design (weight reduction ≥30%, bending strength ≥500MPa). The handle has a pre-embedded cavity that integrates a pressure sensor array (covering more than 90% of the grip area) and a heating resistance wire. The cavity is filled with silicone damping material to absorb vibration. 2. Intelligent and reliable: Built-in sensors monitor riding status in real time, and silicone filling and nano-coating achieve waterproof and shockproof performance; 3. Environmental friendliness: Low-temperature plasma cleaning and nano-coating technology replace highly polluting chemical processes, reducing VOC emissions by 90%; 4. Process efficiency: Integrated molding reduces assembly steps and shortens the production cycle by 40%.

[0020] The above description is merely a preferred embodiment of the present invention. The scope of protection of the present invention is not limited to the above embodiments. All technical solutions falling within the scope of the present invention's concept are within the scope of protection of the present invention. It should be noted that for those skilled in the art, any improvements and modifications made without departing from the principles of the present invention should also be considered within the scope of protection of the present invention.

Claims

1. A manufacturing process for bicycle handlebars, characterized in that, Includes the following steps: S1. Composite lamination molding: The material is pretreated to obtain carbon fiber prepreg and magnesium-aluminum alloy foil. Then, the carbon fiber prepreg and magnesium-aluminum alloy foil are alternately laid and finally vacuum hot-pressed for curing. S1.1 Material pretreatment: The carbon fiber prepreg is thawed at room temperature for 24 hours to remove the surface protective film. At the same time, the magnesium-aluminum plate is subjected to surface alkaline washing and sandblasting to increase the interlayer bonding force and make magnesium-aluminum alloy foil. S1.2 Alternating Lay-up: Carbon fiber prepreg and magnesium-aluminum alloy foil are alternately laid up in the order of "carbon fiber-magnesium-aluminum-carbon fiber", with a total of 6 layers. The lay-up angles are 0° / 90° / 45° and arranged in an alternating pattern to optimize isotropic strength. At the same time, a coupling agent is uniformly coated between each layer during lay-up to prevent delamination. S1.3 Vacuum hot pressing curing: Place the layup into the mold, put it in a vacuum autoclave, evacuate the vacuum, heat it to 150-200℃, pressurize it to 10-12MPa, hold the pressure for 2-3 hours, and then enter the cooling stage, cooling down in a gradient, and naturally cooling to room temperature to form the matrix. S2. Cavity processing and sensor integration: The substrate is laser-cut to form a cavity, where sensors and heating elements are embedded and silicone is injected. S2.1 Using a laser cutting machine, cut a cavity with a trapezoidal cross-section along the length of the handle base; S2.2 Cut the flexible PCB thin film sensor according to the shape of the holding area, attach it to the inner wall of the cavity, and fix the contacts with conductive silver paste; S2.3 Arrange the heating wire in a serpentine path at the bottom of the cavity, and weld copper wires to both ends for lead-out; S2.4 Inject two-component liquid silicone, vacuum degas, and pour after preheating the mold at 40-60℃, then cure at 60-80℃ for 40 minutes; S3. Surface treatment: After plasma cleaning of the substrate, a nano-ceramic coating is deposited, followed by laser engraving of anti-slip texture; S4. Intelligent assembly and testing: The Bluetooth module is packaged, followed by vibration fatigue testing and functional calibration.

2. The handlebar manufacturing process according to claim 1, characterized in that, Step S3 includes: S3.

1. Use radio frequency plasma equipment, introduce argon gas, process for 10 minutes to remove surface organic matter and activate the coating bonding surface; S3.

2. A nano-ceramic coating is deposited on the surface of the handle substrate by magnetron sputtering; S3.

3. Use an ultraviolet laser to engrave a diamond-shaped grid pattern, and repeat 3 times to ensure the texture is clear.

3. The handlebar manufacturing process according to claim 1, characterized in that, Step S4 includes: S4.1 Embed the Bluetooth module into the pre-drilled groove at the end of the handle and fill it with epoxy resin; S4.

2. Using an electromagnetic vibration table, load according to the vibration spectrum and vibrate continuously for 1×10⁻⁶ seconds. 6 After each cycle, check the structure for cracks and ensure the sensors are functioning properly. S4.

3. Calibrate the heating function by applying a 12V voltage, testing the heating curve of the resistance wire, and then making judgments and calibrations. S4.

4. Calibrate the sensor by applying 0-100N pressure using a standard press to calibrate the linearity of the sensor output, followed by judgment and calibration.

4. The handlebar manufacturing process according to claim 1, characterized in that: The nano-ceramic coating comprises, in sequence, a bottom TiN layer, an intermediate Al2O3 layer, and a surface TiN layer.

5. The handlebar manufacturing process according to claim 1, characterized in that: The carbon fiber prepreg is made of T700 grade carbon fiber woven fabric with an epoxy resin content of 35±2% and a single layer thickness of 0.15mm.