Mold for Carbon Fiber Hub Assembly Production
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Solution Overview
Problem
The conventional method for producing carbon fiber bicycle wheels is tedious and difficult to automate due to the need for fine adjustments during the manufacturing process, resulting in long manufacturing times.
Innovation Solution
A method involving a mold with specific disk and spindle configurations is used to shape cord-like curable fabric material into spoke units, allowing for the production of semi-products and hub assemblies with automated processes, reducing manual assembly and manufacturing time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional method of disposing prepreg cloths one by one into a mold is used, then high strength and light weight hub assemblies are produced, but the manufacturing process is tedious and requires long manufacturing time
Solution Approach 1:
The mold is divided into multiple cavities (first cavity, second cavity, third cavity, fourth cavity) that can simultaneously form multiple hub assemblies. Each cavity independently shapes the cord-like curable fabric material into hub assembly components, enabling parallel production while maintaining the high strength properties of individual assemblies.
Solution Approach 2:
The cord-like curable fabric material is pre-formed with a specific configuration before being placed in the mold cavities. The material is pre-impregnated with curable resin and shaped into a cord-like structure that will automatically form the hub assembly geometry when cured, eliminating the need for step-by-step manual assembly during the manufacturing process.
2Manufacturing precision
If conventional method requiring fine adjustments during manufacturing is used, then high precision hub assemblies are produced, but the process is hard to automate
Solution Approach 1:
The cord-like curable fabric material is designed to self-form the hub assembly geometry when placed in the mold cavities and cured. The material's predetermined cord-like structure and the mold cavity design work together to automatically create the precise hub assembly shape without requiring manual adjustment or intervention during the curing process, enabling full automation.
Solution Approach 2:
The manufacturing process utilizes changes in the physical state of the curable resin within the cord-like fabric material. The resin transitions from a viscous state (allowing the material to be disposed into the mold) to a solidified state (forming the precise hub assembly geometry) through curing, eliminating the need for manual adjustment while maintaining high precision.
3Reliability
If conventional step-by-step assembly method is used, then quality control is maintained, but the manufacturing process is too tedious
Solution Approach 1:
Multiple hub assemblies are formed simultaneously in a single manufacturing cycle using multiple mold cavities. The process combines what would traditionally require multiple separate assembly operations into one integrated molding operation, reducing process complexity while maintaining quality control through consistent mold cavity design and curing conditions.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method enables the efficient production of hub assemblies with reduced manufacturing time and facilitates automation, improving the production efficiency of carbon fiber wheel components.
Implementation Method 1
disposing a plurality of prepreg cloths one by one into a mold that contains a wheel rim, spokes, and a hub; fixing them by bonding, and heating the resin of the prepreg cloths to cure
Data Source
AI summary
A mold includes first and second disks, and a spindle connecting centers of first and second disks. The first disk has first linear grooves extending radially from the center to outer periphery of the first disk. The second disk has second linear grooves that extend radially from the center to outer periphery of the second disk and are respectively aligned with first linear grooves. The spindle has first and second end portions that protrude from the first and second disks, respectively. Methods using the mold for producing a semi-product and a hub assembly are also disclosed.