CN110815861A

CN110815861A - Manufacturing method of carbon fiber wheel frame

Info

Publication number: CN110815861A
Application number: CN201810896104.3A
Authority: CN
Inventors: 蔡明仁
Original assignee: Longtai Industry Co Ltd
Current assignee: Marshal Ind Corp; Longtai Industry Co Ltd
Priority date: 2018-08-08
Filing date: 2018-08-08
Publication date: 2020-02-21

Abstract

The manufacturing method of the carbon fiber wheel frame comprises the following steps: preparing a core ring, wherein the core ring comprises a core material which can be differentiated and is annular; continuously winding at least one strand of first dry carbon yarn obliquely around the core ring to form a first wheel frame blank; placing the first wheel frame blank into a mold, and performing processes of vacuumizing, resin injection and heating and shaping to form a second wheel frame blank; taking out the second wheel frame blank from the mold, and differentiating and removing the core material.

Description

Manufacturing method of carbon fiber wheel frame

Technical Field

The invention relates to a manufacturing method of a carbon fiber wheel frame.

Background

In general, a carbon fiber wheel rim is manufactured by impregnating a carbon fiber cloth with a resin, attaching a carbon fiber cloth layer containing the resin to an annular core mold (e.g., an air bag), and then placing the core mold in a mold to be cured and molded by hot pressing.

However, such known techniques have a number of disadvantages. For example, more resin is required to perform the pre-impregnation; the carbon fiber cloth can only be manually adhered but can not be mechanically adhered, which is time-consuming and labor-consuming; the carbon fiber directions of the carbon fiber cloths are not consistent and are not continuous, stress transmission is more easily discontinuous at the mutual lap joint part, the structural integrity is poorer, and the overall strength is greatly reduced; the overlapping part of each carbon fiber cloth is easy to have larger, more and uneven gaps, more and larger bubbles are easy to remain after heating, pressurizing and shaping, and the yield is lower.

Therefore, there is a need to provide a novel and advanced method for manufacturing a carbon fiber wheel rim, so as to solve the above problems.

Disclosure of Invention

The invention mainly aims to provide a carbon fiber wheel frame manufacturing method which is simple, high in efficiency and yield and good in structural strength of the manufactured wheel frame.

In order to achieve the above object, the present invention provides a method for manufacturing a carbon fiber wheel rim, comprising the steps of: preparing a core ring, wherein the core ring comprises a core material which can be differentiated and is annular; continuously winding at least one strand of first dry carbon yarn obliquely around the core ring to form a first wheel frame blank; placing the first wheel frame blank into a mold, and performing processes of vacuumizing, resin injection and heating and shaping to form a second wheel frame blank; taking out the second wheel frame blank from the mold, and differentiating and removing the core material.

Furthermore, a reinforcing member is arranged on the inner side of the core material in a surrounding mode.

Furthermore, the carbon fiber material comprises at least one strand of second dry carbon yarn, the second dry carbon yarn is formed by bundling a plurality of fine carbon fiber yarns, the at least one strand of second dry carbon yarn is obliquely and continuously wound and annularly covered on the plurality of layers of the mould ring, and the winding angles of the second dry carbon yarns of each layer are different.

Further, the core material is selected from polymer materials, plastics, ceramics, salts, metals or waxes.

Further, the polymer material, plastic, ceramic, salt are removed by liquid differentiation.

Further, the plastic or ceramic is pressure-molded with the powder particles.

Further, the metal or wax is removed by melting with heat.

Further, the melting point of the metal or wax is selected to be lower than the melting point of the resin after it is cured and higher than the glass transition temperature (Tg) of the resin.

Furthermore, the first dry carbon yarn is formed by bundling a plurality of fine carbon fiber yarns, the at least one strand of first dry carbon yarn is covered on the core ring in a plurality of layers, and the winding angles of the first dry carbon yarns of each layer are different.

The invention has the beneficial effects that:

the invention provides a carbon fiber wheel frame manufacturing method, wherein dry carbon yarns are continuously surrounded, so that the dry carbon yarns can be more compact, smaller and more uniform in structure and better in structural integrity; the processes of vacuumizing, resin injection and heating and shaping can reduce the generation of bubbles, greatly reduce the failure rate of manufacture and improve the toughness of the structure; the air bag is not needed to be used for assisting in forming, the manufacturing methods of inflation, deflation, slotting and taking out and the like of the air bag can be reduced, and the manufacturing is simple and quick.

Drawings

Fig. 1 to 2 are schematic diagrams illustrating a top blank manufacturing method according to a preferred embodiment of the invention.

Fig. 3 to 4 are schematic views illustrating the fabrication of a core ring according to a preferred embodiment of the present invention.

Fig. 5 to 6 are schematic diagrams illustrating the manufacturing of the first wheel frame blank according to a preferred embodiment of the invention.

FIG. 7 is a schematic view of a second wheel frame blank forming a toroidal groove in accordance with a preferred embodiment of the present invention.

Fig. 8 is a perspective view of a carbon fiber wheel rim according to a preferred embodiment of the present invention.

Fig. 9 is a schematic view of a manufacturing process of a carbon fiber wheel rim according to a preferred embodiment of the invention.

Drawings

1: a carbon fiber wheel frame; 10: a core ring; 11: a core material; 12: a mould ring; 20: a second dry carbon yarn; 30: performing embryo mounting; 40: a reinforcement member; 50: a first dry carbon yarn; 60: a first wheel frame primary blank; 70: a second wheel frame primary blank; 71: annular tire groove.

Detailed Description

The following description is given by way of example only, and is not intended to limit the scope of the invention.

Referring to fig. 1 to 9, which illustrate a preferred embodiment of the present invention, the method for manufacturing a carbon fiber wheel rim of the present invention includes the following steps.

A core ring 10 is provided, the core ring 10 including a core material 11 that is differentiable and annular, the "differentiation" being physical or chemical. In this embodiment, the step of preparing the core ring 10 includes: preparing a mould ring 12; covering the mold ring 12 with at least one carbon fiber material, for example, continuously wrapping and covering the mold ring 12 with at least one strand of second dry carbon yarn 20 obliquely to form an upper blank 30; the core material 11 is arranged on the inner side of the upper blank 30 in a surrounding way; a reinforcing member 40 is disposed around the inner side of the core 11. The core 11 is selected from a polymeric (foamable), plastic, ceramic, salt, metal, wax or other suitable removable material. The mold ring 12 and the reinforcement member 40 are made of a material having high thermal resistance and high hardness (such as carbon fiber composite material), so as to enhance the structural strength of the carbon fiber wheel frame. However, the reinforcing member 40 may not be provided. The carbon fiber material comprises at least one strand of second dry carbon yarn 20, the second dry carbon yarn 20 is formed by bundling a plurality of fine carbon fiber yarns, the at least one strand of second dry carbon yarn 20 is covered on the mold ring 12 in a plurality of layers, the winding angles of the second dry carbon yarns 20 of each layer are different, the tensile strength of the carbon fiber wheel frame 1 can be improved, and the carbon fiber wheel frame is durable and not easy to damage. However, at least one carbon fiber prepreg may be applied to the mold ring to form the upper blank.

Continuously winding and covering the core ring 10 with at least one strand of first dry carbon yarn 50 obliquely to form a first wheel frame blank 60; the first dry carbon yarn 50 is formed by bundling a plurality of fine carbon fiber yarns, the at least one strand of the first dry carbon yarn 50 is covered on the core ring 10 in a plurality of layers, and the winding angles of the first dry carbon yarns 50 of each layer are different, so that the tensile strength of the carbon fiber wheel frame 1 can be improved, and the carbon fiber wheel frame is durable and not easy to damage.

The first wheel frame blank 60 is placed into a mold, and vacuum-pumping, resin-injecting and heat-setting (curing) processes are performed to form a second wheel frame blank 70. The vacuum is applied to fully infiltrate and fill the gaps between the at least one strand of the first and second

dry carbon yarns

50,20, thereby improving the integrity and toughness of the carbon fiber wheel frame 1. In this step, it is not necessary to provide internal pressure to push the first wheel frame blank 60 toward the inner surface of the mold, and the core material 11 will not deform under any stress except for thermal expansion, thereby increasing the success rate of the product.

The second wheel frame blank 70 is removed from the mold and the core 11 is differentiated and removed. Wherein the polymer material, plastic, ceramic, and salt are removed by liquid differentiation, the plastic or ceramic can be formed by powder pressing, the liquid can be water or other solvent, and the liquid can separate, decompose, or melt the core material 11; the metal or wax may be removed by melting with heat. If the metal or wax is used for the core material 11, the temperature of the heat setting process is lower than the melting point of the core material 11, and the resin may have different melting points after being cured according to the time of the heat setting process, and generally, a relatively higher melting point may be obtained for a longer time. For example, the melting point of the resin after being cured can reach 230 ℃ after the resin is heated and shaped at 180 ℃ of the glass transition point temperature of the resin for 30 to 45 minutes. The melting point of the metal or wax is lower than the melting point of the resin after curing and higher than the glass transition temperature (Tg) of the resin, for example, the melting point of the core material 11 is 200 ℃, the glass transition temperature of the resin is 180 ℃, the melting point of the resin after curing is 230 ℃, so that the core material 11 can be removed by heating and melting at a temperature higher than 200 ℃ but lower than 230 ℃.

Finally, a portion of the second wheel frame blank 70 is removed to form a circumferential groove 71 for mounting a tire, and the step of forming the circumferential groove 71 may be performed after removing the core 11. It should be noted that, the at least one first dry carbon yarn may also be directly and continuously wound around the core material without the upper blank, and an annular recess may be directly formed on the second wheel frame blank, and the annular recess may be used for installing a tube tire, for example.

In summary, the dry carbon yarns of the present invention are continuously wrapped so that the dry carbon yarns are more compact, less gapped, smaller and more uniform in structure, and have better structural integrity; the processes of vacuumizing, resin injection and heating and shaping can reduce the generation of bubbles, greatly reduce the failure rate of manufacture and improve the toughness of the structure; the air bag is not needed to be used for assisting in forming, the manufacturing methods of inflation, deflation, slotting and taking out and the like of the air bag can be reduced, and the manufacturing is simple and quick.

Claims

1. A manufacturing method of a carbon fiber wheel frame is characterized by comprising the following steps:

preparing a core ring, wherein the core ring comprises a core material which can be differentiated and is annular;

continuously winding at least one strand of first dry carbon yarn obliquely around the core ring to form a first wheel frame blank;

placing the first wheel frame blank into a mold, and performing processes of vacuumizing, resin injection and heating and shaping to form a second wheel frame blank;

taking out the second wheel frame blank from the mold, and differentiating and removing the core material.

2. The method of manufacturing a carbon fiber wheel rim according to claim 1, wherein the step of preparing the core ring comprises:

preparing a mould ring;

covering the mold ring with at least one carbon fiber material to form an upper blank;

the core material is arranged on the inner side of the upper blank in a surrounding mode.

3. The method of claim 2, further comprising looping a reinforcement around the inside of the core.

4. The method of manufacturing a carbon fiber wheel rim as claimed in claim 2, wherein the carbon fiber material includes at least one second dry carbon yarn, the second dry carbon yarn is formed by bundling a plurality of fine carbon fiber yarns, the at least one second dry carbon yarn is continuously wound obliquely around the mold rings in several layers, and the winding angles of the second dry carbon yarns of the respective layers are different.

5. The method of manufacturing a carbon fiber rim according to claim 1, wherein the core material is selected from a polymer material, a plastic, a ceramic, a salt, a metal, or a wax.

6. The method of claim 5, wherein the polymer material, plastic, ceramic, or salt is removed by liquid differentiation.

7. The method for manufacturing a carbon fiber wheel rim according to claim 5, wherein the plastic or ceramic is pressure-molded with powder particles.

8. The method for manufacturing a carbon fiber wheel rim according to claim 5, wherein the metal or wax is removed by melting with heat.

9. The method of claim 8, wherein the metal or wax is selected to have a melting point lower than the melting point of the resin after curing and higher than the glass transition point of the resin.

10. The carbon fiber wheel frame as claimed in claim 1, wherein the first dry carbon yarn is formed by bundling a plurality of fine carbon fiber yarns, the at least one first dry carbon yarn is wrapped around the core ring in a plurality of layers, and the wrapping angles of the first dry carbon yarns in the respective layers are different.