DE10005573A1 - Production of bicycle components comprises preparing a molding of a component in the form of a foamed metal body, winding the molding with one or more fiber composite plastics impregnated with adhesive and hardening - Google Patents

Abstract

Production of bicycle components, especially frame, handlebar and saddle support comprises preparing a molding of a component in the form of a foamed metal body; completely or partially winding the molding with one or more fiber composite plastics impregnated with adhesive; and hardening. Preferred Features: The molding is wound with the fiber at a constant or changing angle of 1-89 [deg]. The adhesive is a resin. The wound molding is hardened by pressing at a pressure of 1-24 bar.

Description

The present invention relates to a method for producing bicycle components, in particular special bicycle frames, bicycle handlebars and seat posts.

Bicycles and bicycle components of high load capacity are still quite expensive today. In many cases, this is due to the expensive manufacturing processes. There are essentially three processes for the production of carbon components. These are:

• 1. winding process on a core,
• 2. resin injection process (e.g. RTM process) and  
• 3. Prepreg technique using the manual laminate process.

Carbon bike frames are now largely manufactured using prepreg technology. This creates a two-part shape corresponding to the bicycle frame with tapes or fabric ben laid out by hand and coated with a resin. After lamination, the two mold halves in plastic sleeves (prepregs) and the air is sucked out. These prepregs are then removed in an autoclave under pressure and temperature hardened. Hardening under pressure and heat increases the strength of the driver frame and improves its surface quality. Finally, the prepreg is removed removed and the two halves are glued together and reworked. Main cost The drivers of this technology are the prepreg material itself (can only be used once den) and the complex lamination of many thin individual layers of tape or fabric.

The resin injection process (e.g. RTM process) uses finished "dry" tapes or fabric layers under pressure soaked with a thin resin (injected). Leave it complex structures can be created with it, but there is the disadvantage that an even distribution of resin, if possible without air influence, is required in the component and the components produced by this method do not have the strength of components achieve that are made by the winding process or the prepreg technique.

The present invention is therefore based on the object of cheaper bicycles and to provide bicycle components of high resilience.

According to the invention, this object is achieved by a method for producing driving wheel components, in particular bicycle frames, bicycle handlebars and seat posts, which comprises the following steps:

• a) Providing a blank of a bicycle component in the form of a foamed Metal body,  
• b) full or partial wrapping of the blank with one or more fiber composite plastic (s) impregnated with adhesive, and
• c) curing the wrapped blank in a shape corresponding to its contour.

It can be provided that the blank is machined before step b). The Machining can include the familiarization. B. a groove in the final state of Bicycle component results in an integrated cable duct, or a hole for cables, one Serve recess for electronic components or similar components.

Furthermore, according to a further embodiment of the invention, it can be provided that around the blank with a fiber made of a fiber composite plastic soaked in adhesive is wrapped. For example, the Toray T300 carbon fiber can be used.

The blank can be wrapped with a constant or changing fiber feed become. The fiber feed can be in the range from 0.5 m / min to 25 m / min.

It can also be provided that the blank with the fiber under a constant or changing angle is wrapped in the range of 1 to 89 degrees.

According to a further special embodiment of the invention, the blank with several fibers from the same or different fiber soaked in adhesive composite (s) wrapped.

Furthermore, it can be provided that the fibers around the Blank to be wrapped.  

In particular, it can be provided that the fibers at the same time with a constant or changing the fiber feed around the blank.

The fibers can also at the same time at a constant or changing angle Range from 1 to 89 degrees around the blank.

It can also be provided that the fibers are in succession with the same or with under different fiber feed / fiber feeds are wrapped around the blank.

It is also conceivable that the fibers successively under or under various angles (n) in the range from 1 to 89 grand are wound around the blank.

According to a further special embodiment of the invention it can be provided that the wrapping is repeated one or more times in whole or in part. This offers a possibility of one of the possibly spatially different loads of the Bicycle component adapted to produce wall thickness and geometry of the bicycle component.

Preferably the adhesive is a resin. Thereby, a thermosetting resin offers a better one re processability as a cold curing resin. For example, epoxy resin can be used be det.

It can also be provided that the wrapped blank by pressing with a pressure in Cured from 1 bar to 24 bar.

In particular, it can be provided that the wrapped blank over a period of time in Range from a few minutes to 2 days. When using a resin as Adhesive time is in the range of 10 to 60 minutes. When curing (baking) in one Autoclaves can range in time from several hours to a day.  

On the other hand, it is also conceivable for the wrapped blank to harden in a vacuum becomes. In this regard, e.g. B. an autoclave can be used.

It can also be provided that the hardened blank is reworked.

The post-processing can include removing adhesive. A rework tion does not have to mean that this is the last step before the completion of the bike component.

Post-processing can also include the application of one or more protections include layer (s).

In addition, it can be provided that one or more of the cured blank Attachment (s) is / are attached. In the case of a bicycle handlebar, the attachments can, for. B. Be a squirrel. With a bicycle frame, it can e.g. B. an attachment to the tension a rear wheel or z. B. a holder for an air pump or water bottle act.

The attachment (s) is / are favorably made by gluing, soldering, welding, riveting or screws attached.

In addition, it can be provided that one or. In the structure of the hardened blank several parts are introduced. This will integrate components like e.g. B. a lighting system or an anti-theft device.

Conveniently, the part (s) in the hardened blank are glued, soldered ten, welding, rivets or screws attached.  

According to a further particular embodiment of the invention it can be provided that the blank is provided by the following steps: producing a mixture of at least one metal powder and at least one gas-releasing blowing agent powder, hot compacting this mixture into a semifinished product at a temperature at which the connection of the metal powder particles predominantly by diffusion and at a pressure high enough to prevent the decomposition of the blowing agent, such that the metal particles are in a solid connection with one another and form a gas-tight seal for the gas particles of the blowing agent, heating all or one Part of the semi-finished product produced in this way to a temperature above the decomposition temperature of the blowing agent, preferably in the temperature range of the melting point of the metal used, and cooling of all or only part of the metal body thus foamed first For example, AlSi12 powder mixed with 0.3-0.8% TiH ₂ (titanium hydride) can be pressed into the semi-finished product.

In particular, it can be provided that the heating of the semi-finished product in a targeted manner takes place that the density of the foamed metal body varies spatially. The density areas tion can be continuous, but also discrete. So that the strength of the driving Vary the wheel component spatially and adapt to the respective loads.

The density is advantageously spatially varied in the range from 0.25 to 1.5 g / cm ³ . The foamed metal body is advantageously cooled with a cooling medium.

The cooling medium is advantageously air, water, a water emulsion or any other Combination of the same.

It can also be provided that the entire surface or only one or more parts range (s) of the foamed metal body to a temperature of 20 to 250 ° C abge is / are cooled. This can affect the processability of the adhesive as well as the space strength and resilience of the bicycle component have an influence.  

Finally, it can be provided that the blank in a state in which its tem temperature is above the ambient temperature, is wrapped. This can e.g. B. there be realized that the blank is already wrapped before it goes on the reverse temperature has cooled, and may have the advantage that the adhesive better can be processed and overall time is saved in the manufacture of the bicycle component.

The invention is based on the surprising finding that by using a Metal foam core in the bicycle component and wrapping the same with fiber composite art fabric that is soaked with an adhesive, extremely complex, high-strength optimized for stress Bicycle components, such as. B. bicycle frames, handlebars, seat posts and other bicycle accessories can be produced inexpensively. The geometry of the bicycle components can be Contrary to prepreg technology and the winding process can be chosen arbitrarily, because of Metal foam core remains in the bicycle component, which means that the metal foam core also acts as a supporting element, and therefore not as in the winding process by an opening must be driven out. This means that the bicycle components such. B. Paragraphs sen or taper conically, which makes the bicycle component ideal can adjust the assigned loads. In a normal winding process, dage would driven out of the component after curing, which with additional Processing time and thus would be associated with additional costs.

In addition, the bicycle components can be made of metal in a single production line Produce foam body up to the finished bicycle component. The bicycle component (s) must once after cooling and integrating attachments into the Winding device can be clamped. After wrapping the bike component can directly be taken from the final die from the winder. After The component can still be reworked after pressing and curing time. This post-processing Removing adhesive residues, inserting or attaching components (light, Anti-theft device etc.) or the application of a protective layer.  

With the method according to the invention, bicycle components with strengths as in the prepreg technology with low manufacturing costs as with the winding process pass.

Further features and advantages of the invention result from the claims and from the following description, in the exemplary embodiments with reference to the schematic drawing are explained in detail. It shows:

Figure 1 is a schematic representation of part of the flow of a particular embodiment of the method according to the invention.

Figure 2 is a schematic representation of a winding device for wrapping two in the present case, in other cases also more than two bicycle handlebars according to a special embodiment of the inventive method.

Figure 3 is a schematic representation of a further winding device for wrapping two or more bicycle handlebars according to a further particular embodiment of the inventive method.

Fig. 4 is a schematic representation of the wrapping of a bicycle frame in accordance with another embodiment of the process according to the invention;

Figure 5 shows a bicycle handlebar in various stages of its production according to a particular embodiment of the inventive method.

Fig. 6 is a half of the bicycle handlebar of Figure 5 in detail.

Fig. 7 is a longitudinal sectional view of the area marked A in Fig. 6;

Fig. 8 is a sectional view taken along the line VIII-VIII of Fig. 6;

FIG. 9 is a longitudinal sectional view of the area marked B in FIG. 6; different measures for optimizing the introduction of force are shown in a) and b).

Fig. 10 is a side view of a bicycle frame made in accordance with a particular embodiment of erfindungsge MAESSEN method;

Area 11 in detail marked in Figure 10 with J..; and

Fig. 12 in detail the area marked G in Fig. 10.

Fig. 1 shows schematically a representation of part of the flow of a particular embodiment of the method according to the invention, which is used in the present case for producing a bicycle frame. The steps of producing a mixture of at least one metal powder and at least one gas-releasing blowing agent powder, and compacting this mixture into a semi-finished product at a temperature at which the connection of the metal powder particles takes place predominantly by diffusion and at a pressure that is high enough to achieve the Preventing decomposition of the blowing agent in such a way that the metal particles bond to one another in a fixed connection and form a gas-tight seal for the gas particles of the blowing agent are not shown. The representation of the method begins in Fig. 1 left with the heating of the semi-finished product for the Fahrradrahmen (not shown) in a foam mold 12 in a foam oven 8 to a temperature above the decomposition temperature of the blowing agent, preferably in the temperature range the melting point of the metal used. After foaming, the blank 10 is cooled. Furthermore, the blank 10 is wrapped simultaneously over three Wickelvor devices 18 with three fibers 14 made of the same fiber composite soaked in adhesive. Thereafter, the wrapped blank 10 is cured by pressing in a mold 16 corresponding to its contour.

Fig. 2 shows a schematic representation of a winding device 18 for wrapping egg nes blank 10 according to a particular embodiment of the inventive method for producing two bicycle handlebars. The blank 10 is rotatably clamped at its ends. A fiber 14 is brought from a supply roller 22 to the blank 10 via a plurality of deflection rollers 24 . The supply roller 22 and the deflection rollers 24 are displaceable parallel to the longitudinal extent of the blank 10 . The blank 10 is wrapped with the fiber 14 by rotating it about its own axis, while the supply roller 22 and the deflection rollers 24 are moved to the left and to the right together in FIG. 2, as indicated by the arrow. Of course, it would also be possible for the supply roller 22 and the deflection rollers 24 to remain stationary while the blank is moved to the left or to the right in FIG. 2. The line pattern represents the wrapping of the raw ling 10 made of fiber composite plastic, while the honeycomb pattern represents the blank 10 in the form of a foamed metal body. After wrapping the blank 10 , it is separated into two bicycle handlebars.

Fig. 3 shows a schematic representation of a further winding device 18 for winding two bicycle handlebars according to a further particular embodiment of the method according to the invention. A blank 10 , which is to give two bicycle handlebars, is rotatably clamped at both ends, just as in FIG. 2 . Around the blank 10 who, however, the several fibers 14 wound from the same fiber composite plastic soaked with adhesive. For this purpose, a plurality of supply rollers 22 are arranged in a circular frame 26 . To wrap around the blank 10 , the blank is arranged so that it extends in the longitudinal direction essentially centrally through the circular surface generated by the frame 26 . The frame 26 is rotatable about its perpendicular bisection and, as indicated by the arrows, can be moved horizontally and vertically. This enables the blank 10 to be wrapped with a plurality of fibers 14 at the same time. The wrapping is shown by a check pattern, while the blank 10 is shown in the form of a foamed metal body by a honeycomb pattern.

Fig. 4 shows a schematic representation of the wrapping of a blank 10 of a driving wheel frame according to a further particular embodiment of the method according to the invention. Essentially three of the winding devices 18 shown in FIG. 3 are used for this. The bicycle frame 28 itself is an open frame, as is the case today with specially sprung bicycles, such as, for. B. mountain bikes is used. For wrapping the blank 10 with its rear wheel clamping 30 z. B. attached to a wall mounting device 32 . If the clamping is unstable, the blank can also be stored at other points. Similarly as in Fig. 3, the Wickelvor directions are respectively 18 along a portion of the blank 10 movable. The wrapping is again characterized by a check pattern, while the blank 10 is characterized by a honeycomb pattern in the form of a foamed metal body.

Fig. 5 shows schematically a blank 10 of a bicycle handlebar in various stages of its manufacture according to a particular embodiment of the method according to the invention. At the top, the blank 10 of the bicycle handlebar is shown in the form of a foamed metal body with two holes 34 . Below that, the blank 10 is already made with a hardened wrap 40 made with an adhesive, e.g. B. resin-impregnated fiber composite plastic. By attaching bar ends 36 , the bicycle handlebar 20 results.

FIG. 6 shows one half of the bicycle handlebar 20 from FIG. 5 in detail. Both bar ends 36 are also made according to a special embodiment of the method according to the invention, that is to say they have a core 38 made of a foamed metal and a wrapping 40 made of a fiber composite plastic in one leg, while the other leg of the bar ends 36 is hollow and is pushed onto a respective end of the bicycle handlebar 20 . In the main part of the bicycle handlebar 10 there is a bore 34 for further installation parts.

FIG. 7 shows a longitudinal sectional view of the area identified by A in FIG. 6. From right to left, the density of the metal foam core 38 decreases linearly from 0.9 g / cm ² to 0.4 g / cm ² .

FIG. 8 shows a sectional view along the line VIII-VIII of FIG. 6. A central cable duct 42 and a cable duct 44 resulting from an incorporated rectangular groove can be clearly seen.

Fig. 9 is a longitudinal sectional view of the area marked with B in Fig. 6, wherein in Fig. 9a) a force introduction optimization by uniform increase in thickness around the winding 40 towards the bore 34 , the core 38 tapering, and in Fig. 9b) by Thickening of the winding 40 and tapering of the core 38 in the direction of the bore 34 is achieved.

Fig. 10 shows a side view of a bicycle frame 28 prepared according to a particular embodiment of the method according OF INVENTION dung. The bicycle frame 28 has a variable density of the foamed metal body (not shown) in the region C, as is the case, for. B. is shown in Fig. 7. In area D an integrated cable duct (not shown) extends, as z. B. is shown in Fig. 8. Compared to conventional driving wheel frames, this has the advantage that it does not require sleeves in area E. The bicycle frame can also have an aerodynamic geometry in area F. In area G, the integration of an installation part, such as. B. a light source provided. In area H, the bicycle frame 28 has a tapered tube, while in the area I a, z. B. as shown in Fig. 9b), tapered tube. In the area J, a rear wheel clamp 30 is attached by gluing. The bicycle frame 28 is light and strong and can be produced in a few steps.

FIG. 11 shows the area marked J in FIG. 10 in detail. The rear wheel clamping 30 is glued to the bicycle frame 28 in the area of the adhesive surface 46 characterized by the check pattern. Of course, it can also be screwed or glued and screwed to it. The core 38 is again identified by a honeycomb pattern, while the wrapping 40 is identified by a dashed pattern.

Finally, FIG. 12 shows in detail the area marked G in FIG. 10. The integration of parts 48 can be accomplished by attaching the same to the hardened blank 10 by gluing, soldering, welding, riveting or screwing, as shown in FIG. 12a), or by inserting it into the structure of the hardened blank 10 as shown in Fig. 12b).

With the method according to the invention, bicycle components of ideal geometry can be created and inexpensive to manufacture of high quality and strength. Compared to previously Bicycle components manufactured according to the hand laminate process is the present process faster, with less effort, in larger quantities and therefore more cost-effective with very good quality feasible.

The open in the present description, in the drawings and in the claims Beard features of the invention can be used individually or in any combination essential for the implementation of the invention in its various embodiments his.  

Reference list

8th

Foam oven

10th

blank

12th

Foam mold

14

fiber

16

Mold

18th

Winding device

20th

Bicycle handlebar

22

Supply role

24th

Pulley

26

frame

28

Bicycle frame

30th

Rear wheel clamping

32

Wall mounting

34

drilling

36

Bar ends

38

core

40

Wrapping

42

Cabel Canal

44

Cabel Canal

46

Adhesive surface

48

part
A, B, C, D, E, F, G, H, I, J areas

Claims (30)

1. A method for producing bicycle components, in particular bicycle frames, bicycle handlebars and seat posts, which comprises the following steps:

• a) providing a blank of a bicycle component in the form of a foamed metal body,
• b) full or partial wrapping of the blank with one or more fiber composite plastic (s) soaked in adhesive, and
• c) curing the wrapped blank in a shape corresponding to its contour.

2. The method according to claim 1, characterized in that the blank before step b) is machined. 3. The method according to claim 1 or 2, characterized in that the blank with a Fiber is wrapped from a fiber composite plastic soaked with adhesive. 4. The method according to claim 3, characterized in that the blank with a con constant or changing fiber feed is wrapped. 5. The method according to claim 3 or 4, characterized in that the blank with the company water at a constant or changing angle in the range of 1 to 89 degrees is wrapped. 6. The method according to claim 1 or 2, characterized in that the blank with more Ren fibers from the same or different fiber soaked with adhesive bundle plastic (s) is wrapped. 7. The method according to claim 6, characterized in that the fibers simultaneously or be wrapped around the blank one after the other. 8. The method according to claim 7, characterized in that the fibers simultaneously with egg be wound around the blank in a constant or changing fiber feed.   9. The method according to claim 7 or 8, characterized in that the fibers simultaneously at a constant or changing angle in the range of 1 to 89 degrees around the Blank to be wrapped. 10. The method according to claim 7, characterized in that the fibers in succession with the same or with different fiber feed / fiber feeds around the blank be wrapped. 11. The method according to claim 7 or 10, characterized in that the fibers in succession the one at the same or different angle (s) in the range of 1 to 89 degrees to be wrapped around the blank. 12. The method according to any one of the preceding claims, characterized in that the Wrapping is repeated one or more times in whole or in part. 13. The method according to any one of the preceding claims, characterized in that the Adhesive is a resin. 14. The method according to any one of the preceding claims, characterized in that the wrapped blank by pressing with a pressure in the range of 1 bar to 24 bar is hardened. 15. The method according to claim 14, characterized in that the wrapped blank over a time in the range of a few minutes to 2 days is pressed. 16. The method according to any one of claims 1 to 13, characterized in that the umwic cold blank is cured under pressure in a vacuum envelope.   17. The method according to any one of the preceding claims, characterized in that the cured blank is reworked. 18. The method according to claim 17, characterized in that the post-processing a Ent far away from glue. 19. The method according to claim 17, characterized in that the post-processing an on bring one or more protective layer (s). 20. The method according to any one of the preceding claims, characterized in that one or more attachments are attached to the hardened blank. 21. The method according to claim 20, characterized in that the attachment (s) by Gluing, soldering, welding, riveting or screwing is / are attached. 22. The method according to any one of the preceding claims, characterized in that in the Structure of the hardened blank one or more part (s) is / are introduced. 23. The method according to claim 22, characterized in that the part (s) in the out hardened blank by gluing, soldering, welding, riveting or screwing will become. 24. The method according to any one of the preceding claims, characterized in that the blank is provided by the following steps:

• Producing a mixture of at least one metal powder and at least one gas-releasing blowing agent powder,
• - Hot compacting this mixture into a semi-finished product at a temperature at which the connection of the metal powder particles takes place predominantly by diffusion and at a pressure which is high enough to prevent the decomposition of the blowing agent, such that the metal particles are in a solid connection with one another and are a gastight seal for the gas particles of the blowing agent,
• - Heating up all or part of the semi-finished product thus produced to a temperature above the decomposition temperature of the blowing agent, preferably in the temperature range of the melting point of the metal used and
• Cooling of all or only part of the foamed metal body.

25. The method according to claim 24, characterized in that the heating of the semi-finished product is carried out specifically in such a way that the density of the foamed metal body varies spatially. 26. The method according to claim 25, characterized in that the density varies spatially in the range from 0.25 to 1.5 g / cm ³ . 27. The method according to any one of claims 24 to 26, characterized in that the Ab cooling the foamed metal body with a cooling medium. 28. The method according to claim 27, characterized in that the cooling medium is air, what is a water emulsion or any combination thereof. 29. The method according to any one of claims 24 to 28, characterized in that the entire Surface or only one or more partial area (s) of the foamed metal body is / are cooled to a temperature in the range from 20 ° C to 250 ° C.   30. The method according to any one of claims 24 to 29, characterized in that the blank in a state in which its temperature is above the ambient temperature finds, is wrapped.