A cap-pultrusion forming device for a bicycle carbon spoke

Abstract

This invention relates to the field of bicycle parts technology and discloses a pultrusion molding equipment for bicycle carbon spokes, comprising: a frame; a roll forming mechanism for roll forming impregnated carbon yarn bundles into carbon fiber rod spokes; a thermosetting molding mechanism for hot-pressing and curing the ends of the roll-formed carbon fiber rod spokes; a traction module mechanism for driving the linear movement of mechanical components; a hood extrusion and heating molding mechanism for forming the hood head at the ends of the carbon fiber rod spokes; a cutting mechanism for cutting the processed carbon fiber rod spokes; a winding mechanism for collecting the cut carbon fiber rod spokes into a coil; and a control panel for receiving and outputting signals to control the operation of the mechanism. This invention achieves integrated molding of the hood head and spoke body, resulting in high product quality and reliable performance; it also compresses the continuous process flow, significantly reducing the number of assembly steps; and it reduces sources of assembly errors, leading to better product consistency.

Description

Technical Field

[0001] This invention relates to the field of bicycle parts technology, and in particular to a pultrusion molding apparatus for the cap of a bicycle carbon spoke. Background Technology

[0002] Currently, the mainstream carbon fiber spoke technology solutions on the market typically adopt a three-section assembly design, mainly including: the carbon fiber spoke body, the metal cap, and the metal teeth cap. The typical manufacturing process of this solution is: prefabricated metal teeth caps and metal caps are respectively fitted onto both ends of the carbon fiber spoke body, and then the three parts are physically bonded and fixed through molding and adhesive.

[0003] This "metal cap-carbon spoke body-metal tooth cap" configuration is essentially a mechanical / adhesive composite structure of dissimilar materials relying on physical extrusion and adhesive bonding. Although this approach has become the mainstream technology in the current market, it still faces a series of inherent technical bottlenecks stemming from the characteristics of dissimilar materials in both practical applications and theoretical levels. These bottlenecks are specifically manifested in the following aspects: 1. Interface problems caused by joining dissimilar materials.

[0004] Carbon fiber composites and metallic materials differ significantly in their physical, chemical, and mechanical properties, making the interface between them a weak point in the entire spoke structure. This is mainly manifested in the following ways: Galvanic corrosion risk: In humid environments, direct contact between carbon fiber (as the cathode) and reactive metals (such as aluminum alloy cap tips, as the anode) can form a galvanic cell circuit, triggering galvanic corrosion. This will continuously weaken the effective cross-section and structural strength of the metal parts, seriously threatening the long-term reliability and lifespan of the spokes.

[0005] Thermodynamic property mismatch: Carbon fiber and metal have significantly different coefficients of thermal expansion. When subjected to cyclic changes in outdoor temperature, the different degrees of expansion and contraction between the two will generate huge thermal stress at the interface.

[0006] 2. Mechanical performance bottleneck: The key to strength lies in stress concentration. Structural defects and stress concentration: To accommodate metal inserts and enhance connections, the volume of the carbon fiber ends needs to be locally enlarged. These designs and methods cause stress to concentrate sharply at these geometric abrupt changes and structural defects when the spokes are under stress, becoming the source of fatigue failure.

[0007] Failure under complex stress: When a wheel is subjected to lateral forces and torque, the excellent axial tensile strength of carbon fiber is difficult to translate into equally superior torsional and bending resistance. In addition, quality fluctuations of the adhesive, fatigue aging, and slight displacement of the mechanically fitted structure under high loads are all potential failure modes.

[0008] 3. Manufacturing process and cost bottlenecks: the challenge of achieving both precision and mass production. The complex manufacturing process drives up costs: producing a single carbon fiber spoke is not a streamlined assembly line operation, but rather involves multiple isolated processes such as "metal processing → pre-treatment of the connecting structure → carbon fiber body molding → metal-carbon fiber connection assembly." These high demands on processing precision and manual skills make mass production costs and product consistency a significant challenge.

[0009] In summary, the bottlenecks in existing carbon fiber spoke technology at the material, mechanical, and manufacturing levels can be attributed to the fundamental contradiction arising from the "heterogeneous material connection" between metallic materials and carbon fiber composites. For a long time, technological advancements in this field have primarily focused on alleviating these problems through more complex connection structures, more precise assembly processes, or more expensive adhesives. However, these "filling the gaps" approaches have failed to fundamentally eliminate the inherent defects caused by the fundamental differences in material properties.

[0010] Therefore, improvements are needed. Summary of the Invention

[0011] The technical problem solved by the present invention is to address the deficiencies in the prior art by providing a pultrusion molding equipment for bicycle carbon spokes to solve the problems mentioned in the background art.

[0012] To solve the above-mentioned technical problems, the technical solution adopted by the present invention is as follows: a pultrusion molding equipment for bicycle carbon spokes, comprising: a frame for mounting and supporting mechanical components; a roll forming mechanism mounted on the frame for roll forming carbon fiber round rod spokes by rolling impregnated carbon yarn bundles; a thermosetting molding mechanism mounted on the frame for hot-pressing and curing the ends of the roll-formed carbon fiber round rod spokes; and a traction module mechanism mounted on the frame. The assembly mechanism drives the linear movement of mechanical components; the cap-head extrusion and heating forming mechanism, mounted on the traction module mechanism, forms cap heads on the ends of carbon fiber round bar spokes; the cutting mechanism, mounted on the frame, cuts the processed carbon fiber round bar spokes; the winding mechanism, mounted on the frame, collects the cut carbon fiber round bar spokes to form a coil; and the control panel receives and outputs signals to control the operation of the mechanism.

[0013] Furthermore, the roll forming mechanism includes a mounting base disposed on the frame, a first pressure roller disposed on the mounting base, and a second pressure roller adapted to the first pressure roller; the first pressure roller and the second pressure roller are provided with one or more forming grooves, and the impregnated carbon yarn bundle is pressed by the first pressure roller and the second pressure roller to form carbon fiber round rod spokes.

[0014] Furthermore, the roll forming mechanism includes a guide roller disposed on the front side of the first pressure roller and the second pressure roller, a limiting plate disposed on the rear side of the guide roller, and a shaping roller group disposed on the rear side of the first pressure roller and the second pressure roller; the guide roller is used to guide the impregnated carbon yarn bundle to the limiting plate; the limiting plate is provided with a V-groove for guiding the impregnated carbon yarn bundle to the first pressure roller and the second pressure roller; the shaping roller group shapes the side of the carbon fiber round bar spokes after passing through the first pressure roller and the second pressure roller.

[0015] Further, the thermosetting molding mechanism includes an upper molding assembly and a lower molding assembly disposed below the upper molding assembly; the upper molding assembly includes a first telescopic member, a first slide disposed at the driving end of the first telescopic member, a first heating module disposed on the first slide, a first mold pressing block connected to the first heating module, and a first temperature measuring thermocouple disposed on the first mold pressing block; the first mold pressing block is provided with one or more first molding parts for hot pressing and curing; the lower molding assembly includes a second telescopic member, a second slide disposed at the driving end of the second telescopic member, a second heating module disposed on the second slide, a second mold pressing block connected to the second heating module, and a second temperature measuring thermocouple disposed on the second mold pressing block; the second mold pressing block is provided with one or more second molding parts for hot pressing and curing; the upper molding assembly and the lower molding assembly drive each other to hot press and cure the ends of the rolled carbon fiber round bar spokes.

[0016] Furthermore, the traction module mechanism includes a base plate disposed on the frame, a drive motor mounted on the base plate, a lead screw connected to the output end of the drive motor, a guide rail arranged parallel to the lead screw, and a sliding seat disposed on the guide rail; the drive motor drives the lead screw to rotate, and the sliding seat moves linearly along the guide rail.

[0017] Furthermore, the cap head extrusion heating molding mechanism includes a base mounted on the traction module mechanism, a third telescopic member disposed on the base, a first molding die assembly connected to the first driving end of the third telescopic member, a second molding die assembly connected to the second driving end of the third telescopic member, and a cap head molding assembly disposed on one side of the first molding die assembly and the second molding die assembly; the first molding die assembly has one or more first cavities; the second molding die assembly has one or more second cavities; the cap head molding assembly includes a fourth telescopic member and a molding plate disposed on the telescopic end of the fourth telescopic member; the third telescopic member drives the first molding die assembly and the second molding die assembly to move relative to each other to clamp the carbon fiber round bar spokes, and the first cavity and the second cavity form the cavity of the carbon fiber round bar spoke cap; the fourth telescopic member drives the molding plate to extrude the end portion of the carbon fiber round bar spokes into the cavity to form the carbon fiber round bar spoke cap.

[0018] Furthermore, the first molding die assembly includes a third heating module and a first die connected to the third heating module; the third heating module is used to heat the first die; the second molding die assembly includes a fourth heating module and a second die connected to the fourth heating module; the fourth heating module is used to heat the second die.

[0019] Furthermore, a third temperature-measuring thermocouple is included, which is disposed on the first molding die assembly and / or the second molding die assembly, and is used to measure temperature.

[0020] Furthermore, the cutting mechanism includes a fifth telescopic member, a slide rail disposed in the telescopic direction of the fifth telescopic member, a cutting motor disposed on the slide rail, and a cutting disc disposed at the output end of the cutting motor; the fifth telescopic member drives the cutting motor to move along the slide rail, and the cutting disc cuts the carbon fiber round bar spokes.

[0021] Furthermore, the winding mechanism includes a magnetic powder brake, an unwinding roller for unwinding the film, a guide roller for guiding the film, a film platform for receiving the cut carbon fiber round bar spokes, a winding roller for winding the film receiving the carbon fiber round bar spokes, and a winding motor; the magnetic powder brake is connected to the unwinding roller, and the winding motor is connected to the winding roller.

[0022] Compared with the prior art, the beneficial effects of the present invention are as follows: 1. Fundamentally eliminates interface failure issues caused by joining dissimilar materials: This equipment uses a cap-end extrusion and heating forming mechanism to directly extrude and heat the ends of carbon fiber round rod spokes to form a cap-end made entirely of carbon fiber. The spokes produced in this way have a one-piece all-carbon fiber structure, completely avoiding the use of metal cap-ends. This not only completely eliminates the risk of galvanic corrosion but also eliminates the thermal stress problem caused by the mismatch in the thermal expansion coefficients of metal and carbon fiber, significantly improving the long-term reliability and lifespan of the spokes in complex outdoor environments.

[0023] 2. Significantly improved spoke mechanical properties and fatigue life: Because the visor and spoke body are a continuous fiber-reinforced integrated structure, there are no geometric abrupt changes or structural defects caused by accommodating metal inserts in traditional designs. This avoids stress concentration, resulting in more uniform stress distribution on the spokes when subjected to axial tension, lateral force, and torque. Simultaneously, it eliminates potential failure modes such as adhesive aging and slight displacement of the mechanical interlocking structure, thereby significantly improving the overall structural strength, torsional and bending resistance, and fatigue resistance of the spokes.

[0024] 3. Significantly simplified manufacturing process, reduced production costs, and improved product consistency: This equipment integrates multiple processes such as roll forming, end thermosetting, cap extrusion forming, cutting, and winding, forming a continuous assembly line system. This changes the traditional complex model of multi-process, multi-equipment assembly relying on manual skills and adhesives, realizing automated and integrated production of carbon fiber spokes from raw materials to finished products. The simplified process reduces reliance on high-precision machining and manual skills, effectively improving production efficiency, reducing mass production costs, and ensuring a high degree of consistency in product performance. Attached Figure Description

[0025] Figure 1 This is a schematic diagram of the structure of the present invention.

[0026] Figure 2 This is a schematic diagram of the structure of the present invention from another angle.

[0027] Figure 3 This is a schematic diagram of the structure of the present invention.

[0028] Figure 4 This is a schematic diagram of the roll forming mechanism.

[0029] Figure 5 This is a schematic diagram of the roll forming mechanism.

[0030] Figure 6 This is a schematic diagram of a thermosetting molding mechanism.

[0031] Figure 7 This is a schematic diagram of a thermosetting molding mechanism.

[0032] Figure 8 This is a schematic diagram of the traction module mechanism and the cap extrusion heating forming mechanism.

[0033] Figure 9 This is a schematic diagram of the traction module mechanism.

[0034] Figure 10 This is a schematic diagram of the cap head extrusion heating forming mechanism.

[0035] Figure 11 This is a schematic diagram of the cap head extrusion heating forming mechanism.

[0036] Figure 12 This is a schematic diagram of the structure of the first molding die assembly.

[0037] Figure 13 This is a schematic diagram of the structure of the second molding die assembly.

[0038] Figure 14 This is a structural schematic diagram of the hat head molding component.

[0039] Figure 15 This is a schematic diagram of the cutting mechanism.

[0040] Figure 16 This is a schematic diagram of the winding mechanism.

[0041] Figure 17 This is a schematic diagram of the winding mechanism.

[0042] Reference numerals: 1. Frame; 2. Roll forming mechanism; 3. Thermosetting forming mechanism; 4. Traction module mechanism; 5. Cap extrusion heating forming mechanism; 6. Cutting mechanism; 7. Winding mechanism; 8. Control panel; 9. Mounting base; 10. First pressure roller; 11. Second pressure roller; 12. Forming groove; 13. Guide roller; 14. Limiting plate; 15. Shaping roller group; 16. V-groove; 17. Upper die pressing assembly; 18. Lower die pressing assembly; 19. First telescopic component; 20. First slide block; 21. First heating module; 22. First die pressing block; 23. First temperature measuring thermocouple; 24. First forming part; 25. Second telescopic component; 26. Second slide block; 27. Second heating module; 28. Second die pressing block; 29. ​​Second temperature measuring thermocouple 30. Second forming section; 31. Substrate; 32. Drive motor; 33. Lead screw; 34. Guide rail; 35. Sliding seat; 36. Seat body; 37. Third telescopic component; 38. First forming mold assembly; 39. Second forming mold assembly; 40. Cap forming assembly; 41. First cavity; 42. Second cavity; 43. Fourth telescopic component; 44. Forming plate; 45. Third heating module; 46. First mold; 47. Fourth heating module; 48. Second mold; 49. Third temperature measuring thermocouple; 50. Fifth telescopic component; 51. Slide rail; 52. Cutting motor; 53. Cutting disc; 54. Magnetic powder brake; 55. Feeding roller; 56. Guide roller; 57. Film platform; 58. Taking roller; 59. Rewinding motor. Detailed Implementation

[0043] The present invention will now be described in further detail with reference to the accompanying drawings.

[0044] The embodiments described with reference to the accompanying drawings are exemplary and intended to explain this application, and should not be construed as limiting this application. In the description of this application, it should be understood that the terms "center," "longitudinal," "lateral," "length," "width," "thickness," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," "clockwise," and "counterclockwise," etc., indicating orientation or positional relationships based on the orientation or positional relationships shown in the accompanying drawings, are only for the convenience of describing this application 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, and therefore should not be construed as limiting this application. Furthermore, 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 indicated technical features. Thus, a feature defined with "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this application, "several" or "more than" means two or more, unless otherwise explicitly specified. In this application, unless otherwise expressly specified and limited, the terms "installation," "connection," "linking," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this application according to the specific circumstances. In this application, unless otherwise expressly specified and limited, "above" or "below" a second feature can include direct contact between the first and second features, or it can include contact between the first and second features through another feature between them. Moreover, "above," "over," and "on top" of a second feature includes the first feature being directly above or diagonally above the second feature, or simply indicates that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" of a second feature includes the first feature being directly above or diagonally above the second feature, or simply indicates that the first feature is at a lower horizontal level than the second feature.

[0045] In view of the technical problems described in the background art, such as Figure 1-17As shown, a pultrusion molding apparatus for bicycle carbon spokes is provided, comprising: a frame 1 for mounting and supporting mechanical components; a roll forming mechanism 2 mounted on the frame 1 for roll forming impregnated carbon yarn bundles into carbon fiber rod spokes; a thermosetting molding mechanism 3 mounted on the frame 1 for thermosetting and curing the ends of the roll-formed carbon fiber rod spokes; and a traction module mechanism 4 mounted on the frame 1 for driving the machine. The mechanical components move linearly; a cap-head extrusion and heating forming mechanism 5 is mounted on the traction module mechanism 4, and is used to form cap heads on the ends of carbon fiber round bar spokes; a cutting mechanism 6 is mounted on the frame 1, and is driven to cut the processed carbon fiber round bar spokes; a winding mechanism 7 is mounted on the frame 1, and is driven to collect the cut carbon fiber round bar spokes to form a coil; and a control screen 8 is used to receive and output signals to control the operation of the mechanism.

[0046] This invention provides a pultrusion molding equipment for bicycle carbon spokes. The equipment mainly includes: a frame 1, a roll forming mechanism 2, a thermosetting forming mechanism 3, a traction module mechanism 4, a pultrusion heating forming mechanism 5, a cutting mechanism 6, a winding mechanism 7, and a control panel 8.

[0047] The frame 1 serves as the installation base for the entire equipment and is made of high-strength steel profiles to ensure that each functional mechanism can be installed accurately and stably in its predetermined position.

[0048] The roll forming mechanism 2 is installed at one end of the frame 1 and is used to continuously roll carbon yarn bundles pre-impregnated with thermosetting resin to form carbon fiber round rod spokes with a circular cross section.

[0049] The thermosetting molding mechanism 3 is mounted on the frame 1, adjacent to the discharge end of the roll forming mechanism 2. Since the end of the carbon fiber round bar spoke requires a straight round bar section (10mm in length) to be bonded to the metal tooth cap, this section is thermoformed by compression molding at this location. The molding temperature is approximately 150°C, and the time is approximately 5 minutes. (Note: Compression molding is performed after the spoke length has been stretched.) The traction module mechanism 4 is mounted on the frame 1 and is set in the horizontal direction. It is used to drive the cap head extrusion heating and forming mechanism 5 to make linear reciprocating motion along the axial direction of the carbon fiber round bar spokes, so as to facilitate the processing operation of the carbon fiber round bar spokes by each mechanism.

[0050] The cap-head extrusion and heating molding mechanism 5 is the core component of the entire equipment, and it is fixedly installed on the traction module mechanism 4. It moves linearly under the drive of the traction module mechanism 4. Traditionally, the ends of carbon fiber round bar spokes are molded by using adhesives to bond the metal cap head to the ends of the carbon fiber round bar spokes. However, the core technological breakthrough in this solution lies in eliminating the concept of the "cap head" as a separate part—the cap head is no longer a component that needs to be "installed," but rather a natural extension of the carbon fiber round bar spokes. The carbon fiber round bar spokes are integrally composed of continuous carbon fiber reinforced resin matrix composite material from one end to the other, without any mechanical or chemical bonding interfaces in between. This innovation solves the inherent problem of joining dissimilar materials like metal and carbon fiber.

[0051] The cutting mechanism 6 is mounted on the frame 1 and is located at the station between the thermosetting forming mechanism 3 and the cap extrusion heating forming mechanism 5. The cutting mechanism 6 is used to cut the processed carbon fiber round bar spokes to complete the cutting process.

[0052] The winding mechanism 7 is installed on the frame 1 and is used to automatically collect the cut finished carbon fiber spokes to form a coil, which facilitates subsequent processing.

[0053] refer to Figure 4-5 As shown, the roll forming mechanism 2 includes a mounting base 9 disposed on the frame 1, a first pressure roller 10 disposed on the mounting base 9, and a second pressure roller 11 adapted to the first pressure roller 10; the first pressure roller 10 and the second pressure roller 11 are provided with one or more forming grooves 12, and the carbon yarn bundle after being impregnated with glue is pressed by the first pressure roller 10 and the second pressure roller 11 to form carbon fiber round rod spokes.

[0054] The roll forming mechanism 2 includes a guide roller 13 disposed in front of the first pressure roller 10 and the second pressure roller 11, a limiting plate 14 disposed behind the guide roller 13, and a shaping roller group 15 disposed behind the first pressure roller 10 and the second pressure roller 11. The guide roller 13 is used to guide the impregnated carbon yarn bundle to the limiting plate 14. The limiting plate 14 is provided with a V-groove 16 for guiding the impregnated carbon yarn bundle to the first pressure roller 10 and the second pressure roller 11. The shaping roller group 15 shapes the side of the carbon fiber round bar spokes after passing through the first pressure roller 10 and the second pressure roller 11.

[0055] Specifically, the roll forming mechanism 2 includes a mounting base 9 fixed on the frame 1, and a first pressure roller 10 and a second pressure roller 11 rotatably and parallelly arranged on the mounting base 9. The circumferential surfaces of the first pressure roller 10 and the second pressure roller 11 are respectively provided with one or more mutually matching semi-circular forming grooves 12. The number of forming grooves 12 can be set according to the actual number of carbon fiber round rod spokes produced simultaneously. For example, in this embodiment, the number of carbon fiber round rod spokes produced simultaneously is five. When the resin-impregnated carbon yarn bundle passes between the two pressure rollers, it is gradually squeezed and shaped into a round rod shape as the pressure rollers rotate.

[0056] Preferably, the roll forming mechanism 2 further includes a guide roller 13 disposed in front of the first pressure roller 10 and the second pressure roller 11, a limiting plate 14 disposed behind the guide roller 13, and a shaping roller group 15. The guide roller 13 is used to gather and guide the carbon yarn bundle after impregnation and curing to the limiting plate 14. The limiting plate 14 is provided with a V-shaped groove 16, the tip of which points to the entrance of the forming groove 12 of the pressure roller, which can further gather the flat carbon yarn bundle and ensure that it enters the space between the first pressure roller 10 and the second pressure roller 11 accurately and smoothly. The shaping roller group 15 is a pair of oppositely arranged rollers, and a semi-circular groove is provided on the circumference of the rollers. When the carbon fiber rod spokes pass through the shaping roller group 15, the shaping roller group 15 squeezes and removes the sharp corners generated by the roll forming on both sides of the carbon fiber rod spokes, making the cross-section of the carbon fiber rod more rounded.

[0057] refer to Figure 6-7 As shown, the thermosetting molding mechanism 3 includes an upper molding assembly 17 and a lower molding assembly 18 disposed below the upper molding assembly 17; the upper molding assembly 17 includes a first telescopic member 19, a first slide 20 disposed at the driving end of the first telescopic member 19, a first heating module 21 disposed on the first slide 20, a first mold 46 pressing block 22 connected to the first heating module 21, and a first temperature measuring thermocouple 23 disposed on the first mold 46 pressing block 22; the first mold 46 pressing block 22 is provided with one or more first molding parts 2 for thermosetting and curing. 4; The lower molding assembly 18 includes a second telescopic member 25, a second slide block 26 disposed at the driving end of the second telescopic member 25, a second heating module 27 disposed on the second slide block 26, a second mold 48 pressing block 28 connected to the second heating module 27, and a second temperature measuring thermocouple 29 disposed on the second mold 48 pressing block 28; the second mold 48 pressing block 28 is provided with one or more second forming parts 30 for hot pressing and curing; the upper molding assembly 17 and the lower molding assembly 18 drive each other to hot press and cure the ends of the rolled carbon fiber round bar spokes.

[0058] The mechanism consists of an upper molding assembly 17 and a lower molding assembly 18. The upper molding assembly 17 includes a first telescopic member 19 (e.g., a cylinder or hydraulic cylinder with telescopic function, preferably a cylinder in this embodiment), a first slide 20 driven by the first telescopic member 19, a first heating module 21 mounted on the first slide 20, a first mold 46 pressure block 22 thermally connected to the first heating module 21, and a first temperature measuring thermocouple 23 for real-time temperature monitoring. The lower surface of the first mold 46 pressure block 22 is provided with one or more first forming parts 24. The first forming parts 24 are designed according to the end shape of the carbon fiber round bar spokes, for example, a semi-circular groove structure can be selected.

[0059] The lower molding assembly 18 has a symmetrical structure and includes a second telescopic member 25, a second slide block 26, a second heating module 27, a second mold 48 pressing block 28, and a second temperature measuring thermocouple 29. The upper surface of the second mold 48 pressing block 28 is provided with a second forming part 30.

[0060] During operation, when a specific segment of the carbon fiber round bar spoke moves between the first mold 46 pressing block 22 and the second mold 48 pressing block 28, the first telescopic member 19 and the second telescopic member 25 extend simultaneously, driving the two mold pressing blocks to close, heating and pressurizing the end of the carbon fiber round bar spoke, so that it is initially solidified and shaped, preparing for the subsequent connection of the metal tooth cap. The first temperature measuring thermocouple 23 and the second temperature measuring thermocouple 29 feed back the temperature signal to the control panel 8 in real time to realize closed-loop temperature control.

[0061] Reference Figure 8-9 As shown, the traction module mechanism 4 includes a base plate 31 disposed on the frame 1, a drive motor 32 mounted on the base plate 31, a lead screw 33 connected to the output end of the drive motor 32, a guide rail 34 arranged parallel to the lead screw 33, and a sliding seat 35 disposed on the guide rail 34; the drive motor 32 drives the lead screw 33 to rotate, and the sliding seat 35 moves linearly along the guide rail 34.

[0062] The driving process of the traction module mechanism 4 is as follows: the servo drive motor 32 receives the instruction from the control panel 8 and drives the lead screw 33 to rotate, thereby driving the sliding seat 35 and the cap extrusion heating and forming mechanism 5 installed on it to move according to the set speed and distance.

[0063] Reference Figure 10-14As shown, the cap extrusion heating and forming mechanism 5 includes a base 36 mounted on the traction module mechanism 4, a third telescopic member 37 disposed on the base 36, a first forming mold assembly 38 connected to the first driving end of the third telescopic member 37, a second forming mold assembly 39 connected to the second driving end of the third telescopic member 37, and a cap forming assembly 40 disposed on one side of the first forming mold assembly 38 and the second forming mold assembly 39; the first forming mold assembly 38 has one or more first cavities 41; the second forming mold assembly 39... The device has one or more second cavities 42; the cap forming assembly 40 includes a fourth telescopic member 43 and a forming plate 44 disposed on the telescopic end of the fourth telescopic member 43; the third telescopic member 37 drives the first forming mold assembly 38 and the second forming mold assembly 39 to move relative to each other to clamp the carbon fiber round bar spokes, and the first cavity 41 and the second cavity 42 form the cavity of the carbon fiber round bar spoke cap; the fourth telescopic member 43 drives the forming plate 44 to squeeze the end portion of the carbon fiber round bar spokes into the cavity to form the carbon fiber round bar spoke cap.

[0064] The first molding die assembly 38 includes a third heating module 45 and a first die 46 connected to the third heating module 45; the third heating module 45 is used to heat the first die 46; the second molding die assembly 39 includes a fourth heating module 47 and a second die 48 connected to the fourth heating module 47; the fourth heating module 47 is used to heat the second die 48.

[0065] The present invention includes a third temperature measuring thermocouple 49, which is disposed on the first molding die assembly 38 and / or the second molding die assembly 39, and the temperature measuring thermocouple is used to measure temperature.

[0066] The mechanism includes: a base 36, a third telescopic member 37 (preferably a dual-axis cylinder or a combination of two single-axis cylinders), a first molding die assembly 38 connected to the first drive end of the third telescopic member 37, a second molding die assembly 39 connected to the second drive end of the third telescopic member 37, and a cap forming assembly 40 disposed beside the first molding die assembly 38 and the second molding die assembly 39.

[0067] The first forming mold assembly 38 includes a third heating module 45 and a first mold 46 connected to the third heating module 45. The inner surface of the first mold 46 has multiple semi-cylindrical first cavities 41. Since this embodiment processes five carbon fiber round rod spokes simultaneously, the number of first cavities 41 and second cavities 42 is five. Similarly, the second forming mold assembly 39 includes a fourth heating module 47 and a second mold 48. The inner surface of the second mold 48 has correspondingly multiple semi-cylindrical second cavities 42. When the third telescopic member 37 drives the first mold 46 and the second mold 48 to close, the corresponding first cavities 41 and second cavities 42 together form a complete circular channel for accommodating the carbon fiber round rod spokes. The center of this channel has a cavity with a diameter larger than the spoke body; this cavity is the forming cavity for the cap (not shown in the figure).

[0068] The cap forming assembly 40 includes a vertically mounted fourth telescopic member 43 (e.g., a telescopic component such as a cylinder or hydraulic cylinder) and a forming plate 44 fixed to the telescopic end of the fourth telescopic member 43. The position of the forming plate 44 corresponds to the closed end of the cavity.

[0069] Its working process is as follows.

[0070] Clamping and Heating: When the traction module mechanism 4 moves the entire cap-head extrusion heating molding mechanism 5 to align with the predetermined cap-head molding position of the continuous carbon fiber round bar spokes, the third telescopic member 37 actuates, driving the first mold 46 and the second mold 48 to close, tightly clamping the carbon fiber round bar spokes and moving forward a set distance. The rear thermosetting molding mechanism 3 heats and cures the left end of the carbon fiber round bar spokes. At this time, the third heating module 45 and the fourth heating module 47 are activated, heating the molds to the preset resin molding temperature to soften the spoke ends.

[0071] Extrusion molding: While being held and heated, the fourth telescopic member 43 extends, driving the forming plate 44 to axially extrude the carbon fiber round rod spoke from the end. Under the pushing force of the forming plate 44 and the constraint of the mold cavity, the heated resin and carbon fiber material at the spoke end undergoes plastic flow, is squeezed and fills the cavity in the middle of the mold, thereby forming an integrated all-carbon fiber cap with an outer diameter larger than the spoke body.

[0072] Curing and Demolding: Maintain pressure and temperature for a period of time to allow the resin in the cap area to fully cure. After curing, the fourth telescopic component 43 retracts, and the third telescopic component 37 opens the first mold 46 and the second mold 48 to complete the molding of the cap.

[0073] Preferably, the cap extrusion heating and forming mechanism 5 is also provided with a third temperature measuring thermocouple 49, which is used to accurately monitor the real-time temperature of the first mold 46 and the second mold 48, and to feed the signal back to the control screen 8.

[0074] like Figure 15 As shown, the cutting mechanism 6 includes a fifth telescopic member 50, a slide rail 51 disposed in the telescopic direction of the fifth telescopic member 50, a cutting motor 52 disposed on the slide rail 51, and a cutting disc 53 disposed at the output end of the cutting motor 52; the fifth telescopic member 50 drives the cutting motor 52 to move along the slide rail 51, and the cutting disc 53 cuts the spokes of the carbon fiber round bar.

[0075] The cutting mechanism 6 includes a fifth telescopic component 50 (such as a cylinder or hydraulic cylinder with telescopic function), a slide rail 51, a cutting motor 52, and a cutting disc 53. When the carbon fiber round bar spokes are processed, the fifth telescopic component 50 drives the cutting motor 52 to move horizontally along the slide rail 51, while the high-speed rotating cutting disc 53 precisely cuts the carbon fiber round bar spokes.

[0076] refer to Figure 16-17 As shown, the winding mechanism 7 includes a magnetic powder brake 54, an unwinding roller 55 for unwinding the film, a guide roller 56 for guiding the film, a film platform 57 for receiving the cut carbon fiber round bar spokes, a winding roller 58 for winding the film receiving the carbon fiber round bar spokes, and a winding motor 59; the magnetic powder brake 54 is connected to the unwinding roller 55, and the winding motor 59 is connected to the winding roller 58.

[0077] The winding mechanism 7 includes a magnetic powder brake 54, an unloading roller 55, a guide roller 56, a film platform 57, a take-up roller 58, and a winding motor 59. Unused protective film rolls are wound onto the unloading roller 55, with the magnetic powder brake 54 providing constant tension. After passing through the guide roller 56, the film is laid flat on the film platform 57. Cut carbon fiber spokes are moved to the film platform 57 by the traction module mechanism 4. The cap-end extrusion heating and forming mechanism 5 releases the carbon fiber spokes. Due to their light weight, the carbon fiber spokes adhere to the film surface without relative movement. The winding motor 59 drives the take-up roller 58 to rotate, winding the film carrying the spokes together with the spokes into a tight roll for subsequent processing. The control panel 8 uses an industrial touchscreen, electrically connected to all motors, telescopic components, heating modules, and sensors of the equipment via a programmable logic controller (PLC). It is used to receive signals, send commands, set process parameters, and monitor the equipment's operating status.

[0078] Its working process is as follows.

[0079] After being impregnated with resin, the continuous carbon yarn bundle passes through the guide roller 13 and the limiting plate 14 in sequence, and then enters the first pressure roller 10 and the second pressure roller 11, where it is continuously pressed into carbon fiber round rod spokes.

[0080] Carbon fiber round rods enter the thermosetting molding mechanism 3, where their ends are heated and pressurized for pre-curing.

[0081] The traction module mechanism 4 drives the cap head extrusion heating and forming mechanism 5 to clamp the carbon fiber round bar spokes and move them to the working position. The predetermined end of the carbon fiber round bar spokes is clamped and directly formed into a cap head of all carbon material through heating and extrusion.

[0082] After the cap head has solidified, the cap head extrusion heating molding mechanism 5 opens the mold and retracts.

[0083] The cutting mechanism 6 cuts the spokes with caps to a set length.

[0084] The cut finished spokes fall onto the film of the winding mechanism 7 and are automatically wound into a roll.

[0085] The above does not limit the technical scope of the present invention in any way. Any modifications, equivalent changes and alterations made to the above embodiments based on the technical essence of the present invention shall still fall within the technical scope of the present invention.

Claims

1. A pultrusion molding machine for the crown of a bicycle carbon spoke, characterized in that, include: A frame for mounting and supporting mechanical components; A roll forming mechanism is mounted on the frame and is used to roll impregnate carbon yarn bundles into carbon fiber round rod spokes. A thermosetting molding mechanism is mounted on a frame and is used to heat-press and cure the ends of the rolled carbon fiber round bar spokes. A traction module mechanism is mounted on the frame and is used to drive the mechanical components to move linearly. A cap head extrusion and heating forming mechanism is installed on the traction module mechanism and is used to form a cap head on the end of the carbon fiber round bar spokes; A cutting mechanism, which is mounted on the frame, is driven to cut the processed carbon fiber round bar spokes; A winding mechanism, mounted on the frame, drives the collection of cut carbon fiber round bar spokes to form a coil; The control panel is used to receive and output signals and control the operation of the mechanism.

2. The pultrusion molding equipment for the crown of a bicycle carbon spoke according to claim 1, characterized in that: The roll forming mechanism includes a mounting base disposed on the frame, a first pressure roller disposed on the mounting base, and a second pressure roller adapted to the first pressure roller; The first and second pressure rollers are provided with one or more forming grooves. The carbon yarn bundles after being impregnated with resin are pressed by the first and second pressure rollers to form carbon fiber round rods and spokes.

3. The pultrusion molding equipment for the crown of a bicycle carbon spoke according to claim 2, characterized in that: The roll forming mechanism includes a guide roller disposed in front of the first pressure roller and the second pressure roller, a limiting plate disposed behind the guide roller, and a shaping roller group disposed behind the first pressure roller and the second pressure roller. The guide roller is used to guide the impregnated carbon yarn bundle to the limiting plate; The limiting plate is provided with a V-groove for guiding the impregnated carbon yarn bundle to the first pressure roller and the second pressure roller; The shaping roller group shapes the side surfaces of the carbon fiber round bar spokes after they have passed through the first pressure roller and the second pressure roller.

4. The pultrusion molding equipment for the crown of a bicycle carbon spoke according to claim 1, characterized in that: The thermosetting molding mechanism includes an upper molding assembly and a lower molding assembly disposed below the upper molding assembly; The upper molding assembly includes a first telescopic member, a first slide block disposed at the driving end of the first telescopic member, a first heating module disposed on the first slide block, a first mold pressing block connected to the first heating module, and a first temperature measuring thermocouple disposed on the first mold pressing block; the first mold pressing block is provided with one or more first molding parts for hot pressing and curing. The lower molding assembly includes a second telescopic member, a second slide block disposed at the driving end of the second telescopic member, a second heating module disposed on the second slide block, a second mold pressing block connected to the second heating module, and a second temperature measuring thermocouple disposed on the second mold pressing block; the second mold pressing block is provided with one or more second forming parts for hot pressing and curing. The upper molding assembly and the lower molding assembly drive each other to hot-press and cure the ends of the carbon fiber round bar spokes after roller pressing.

5. The pultrusion molding equipment for the crown of a bicycle carbon spoke according to claim 1, characterized in that: The traction module mechanism includes a base plate disposed on the frame, a drive motor mounted on the base plate, a lead screw connected to the output end of the drive motor, a guide rail arranged parallel to the lead screw, and a sliding seat disposed on the guide rail; The drive motor drives the lead screw to rotate, and the sliding seat moves linearly along the guide rail.

6. The pultrusion molding equipment for the crown of a bicycle carbon spoke according to claim 1, characterized in that: The cap extrusion heating and forming mechanism includes a base mounted on the traction module mechanism, a third telescopic member disposed on the base, a first forming mold assembly connected to the first driving end of the third telescopic member, a second forming mold assembly connected to the second driving end of the third telescopic member, and a cap forming assembly disposed on one side of the first forming mold assembly and the second forming mold assembly. The first molding die assembly has one or more first cavities; The second molding die assembly has one or more second cavities; The hat-shaped assembly includes a fourth telescopic member and a forming plate disposed on the telescopic end of the fourth telescopic member; The third telescopic component drives the first molding die assembly and the second molding die assembly to move relative to each other to clamp the carbon fiber round bar spokes, and the first cavity and the second cavity form a cavity for the carbon fiber round bar spoke cap. The fourth telescopic component drives the molding plate to squeeze the end portion of the carbon fiber round bar spokes into the cavity to form the carbon fiber round bar spoke cap.

7. The pultrusion molding equipment for the crown of a bicycle carbon spoke according to claim 6, characterized in that: The first molding die assembly includes a third heating module and a first die connected to the third heating module; the third heating module is used to heat the first die. The second molding die assembly includes a fourth heating module and a second die connected to the fourth heating module; the fourth heating module is used to heat the second die.

8. The pultrusion molding equipment for the crown of a bicycle carbon spoke according to claim 6, characterized in that: It includes a third temperature-measuring thermocouple, which is disposed on the first molding die assembly and / or the second molding die assembly, and is used to measure temperature.

9. The pultrusion molding equipment for the crown of a bicycle carbon spoke according to claim 1, characterized in that: The cutting mechanism includes a fifth telescopic member, a slide rail disposed in the telescopic direction of the fifth telescopic member, a cutting motor disposed on the slide rail, and a cutting disc disposed at the output end of the cutting motor. The fifth telescopic component drives the cutting motor to move along the slide rail, and the cutting disc cuts the spokes of the carbon fiber round bar.

10. The pultrusion molding equipment for the crown of a bicycle carbon spoke according to claim 1, characterized in that: The winding mechanism includes a magnetic powder brake, an unwinding roller for unwinding the film, a guide roller for guiding the film, a film platform for receiving the cut carbon fiber round bar spokes, a winding roller for winding the film receiving the carbon fiber round bar spokes, and a winding motor. The magnetic powder brake is connected to the unloading roller, and the winding motor is connected to the winding roller.

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