TWI541148B - Production method and structure of carbon fiber rim - Google Patents

Production method and structure of carbon fiber rim Download PDF

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Publication number
TWI541148B
TWI541148B TW103142076A TW103142076A TWI541148B TW I541148 B TWI541148 B TW I541148B TW 103142076 A TW103142076 A TW 103142076A TW 103142076 A TW103142076 A TW 103142076A TW I541148 B TWI541148 B TW I541148B
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Taiwan
Prior art keywords
carbon fiber
support member
tire
lower support
yarn
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TW103142076A
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TW201620733A (zh
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Shu-Wei Lin
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Shu-Wei Lin
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Priority to TW103142076A priority Critical patent/TWI541148B/zh
Priority to US14/831,010 priority patent/US10005245B2/en
Priority to EP15182627.8A priority patent/EP3028871B1/en
Publication of TW201620733A publication Critical patent/TW201620733A/zh
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Publication of TWI541148B publication Critical patent/TWI541148B/zh

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28—Shaping operations therefor
    • B29C70/40—Shaping or impregnating by compression not applied
    • B29C70/42—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles
    • B29C70/46—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using matched moulds, e.g. for deforming sheet moulding compounds [SMC] or prepregs
    • B29C70/48—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using matched moulds, e.g. for deforming sheet moulding compounds [SMC] or prepregs and impregnating the reinforcements in the closed mould, e.g. resin transfer moulding [RTM], e.g. by vacuum
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28—Shaping operations therefor
    • B29C70/54—Component parts, details or accessories; Auxiliary operations, e.g. feeding or storage of prepregs or SMC after impregnation or during ageing
    • B29C70/545—Perforating, cutting or machining during or after moulding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/68—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts by incorporating or moulding on preformed parts, e.g. inserts or layers, e.g. foam blocks
    • B29C70/86—Incorporated in coherent impregnated reinforcing layers, e.g. by winding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60B—VEHICLE WHEELS; CASTORS; AXLES FOR WHEELS OR CASTORS; INCREASING WHEEL ADHESION
    • B60B21/00—Rims
    • B60B21/02—Rims characterised by transverse section
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60B—VEHICLE WHEELS; CASTORS; AXLES FOR WHEELS OR CASTORS; INCREASING WHEEL ADHESION
    • B60B21/00—Rims
    • B60B21/02—Rims characterised by transverse section
    • B60B21/04—Rims characterised by transverse section with substantially radial flanges
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B60B—VEHICLE WHEELS; CASTORS; AXLES FOR WHEELS OR CASTORS; INCREASING WHEEL ADHESION
    • B60B21/00—Rims
    • B60B21/10—Rims characterised by the form of tyre-seat or flange, e.g. corrugated
    • B60B21/102—Rims characterised by the form of tyre-seat or flange, e.g. corrugated the shape of bead seats
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B60B21/00—Rims
    • B60B21/10—Rims characterised by the form of tyre-seat or flange, e.g. corrugated
    • B60B21/108—Rims characterised by the form of tyre-seat or flange, e.g. corrugated the surface of bead seats
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60B—VEHICLE WHEELS; CASTORS; AXLES FOR WHEELS OR CASTORS; INCREASING WHEEL ADHESION
    • B60B25/00—Rims built-up of several main parts ; Locking means for the rim parts
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B60B—VEHICLE WHEELS; CASTORS; AXLES FOR WHEELS OR CASTORS; INCREASING WHEEL ADHESION
    • B60B5/00—Wheels, spokes, disc bodies, rims, hubs, wholly or predominantly made of non-metallic material
    • B60B5/02—Wheels, spokes, disc bodies, rims, hubs, wholly or predominantly made of non-metallic material made of synthetic material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2101/00—Use of unspecified macromolecular compounds as moulding material
    • B29K2101/10—Thermosetting resins
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/06—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts
    • B29K2105/08—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts of continuous length, e.g. cords, rovings, mats, fabrics, strands or yarns
    • B29K2105/10—Cords, strands or rovings, e.g. oriented cords, strands or rovings
    • B29K2105/101—Oriented
    • B29K2105/102—Oriented circumferentially
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2307/00—Use of elements other than metals as reinforcement
    • B29K2307/04—Carbon
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/32—Wheels, pinions, pulleys, castors or rollers, Rims
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60B—VEHICLE WHEELS; CASTORS; AXLES FOR WHEELS OR CASTORS; INCREASING WHEEL ADHESION
    • B60B1/00—Spoked wheels; Spokes thereof
    • B60B1/003—Spoked wheels; Spokes thereof specially adapted for bicycles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60B—VEHICLE WHEELS; CASTORS; AXLES FOR WHEELS OR CASTORS; INCREASING WHEEL ADHESION
    • B60B21/00—Rims
    • B60B21/06—Rims characterised by means for attaching spokes, i.e. spoke seats
    • B60B21/062—Rims characterised by means for attaching spokes, i.e. spoke seats for bicycles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60B—VEHICLE WHEELS; CASTORS; AXLES FOR WHEELS OR CASTORS; INCREASING WHEEL ADHESION
    • B60B2310/00—Manufacturing methods
    • B60B2310/30—Manufacturing methods joining
    • B60B2310/321—Manufacturing methods joining by overmolding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60B—VEHICLE WHEELS; CASTORS; AXLES FOR WHEELS OR CASTORS; INCREASING WHEEL ADHESION
    • B60B2310/00—Manufacturing methods
    • B60B2310/80—Filament winding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60B—VEHICLE WHEELS; CASTORS; AXLES FOR WHEELS OR CASTORS; INCREASING WHEEL ADHESION
    • B60B2320/00—Manufacturing or maintenance operations
    • B60B2320/10—Assembling; disassembling
    • B60B2320/14—Assembly devices for divided rims
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60B—VEHICLE WHEELS; CASTORS; AXLES FOR WHEELS OR CASTORS; INCREASING WHEEL ADHESION
    • B60B2360/00—Materials; Physical forms thereof
    • B60B2360/30—Synthetic materials
    • B60B2360/33—Synthetic foams
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60B—VEHICLE WHEELS; CASTORS; AXLES FOR WHEELS OR CASTORS; INCREASING WHEEL ADHESION
    • B60B2360/00—Materials; Physical forms thereof
    • B60B2360/30—Synthetic materials
    • B60B2360/34—Reinforced plastics
    • B60B2360/341—Reinforced plastics with fibres
    • B60B2360/3416—Carbone fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60B—VEHICLE WHEELS; CASTORS; AXLES FOR WHEELS OR CASTORS; INCREASING WHEEL ADHESION
    • B60B2360/00—Materials; Physical forms thereof
    • B60B2360/30—Synthetic materials
    • B60B2360/34—Reinforced plastics
    • B60B2360/348—Resins
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60B—VEHICLE WHEELS; CASTORS; AXLES FOR WHEELS OR CASTORS; INCREASING WHEEL ADHESION
    • B60B2360/00—Materials; Physical forms thereof
    • B60B2360/30—Synthetic materials
    • B60B2360/36—Composite materials
    • B60B2360/366—Composite materials comprising foams, e.g. synthetic or metal foams
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
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    • B60B2360/00—Materials; Physical forms thereof
    • B60B2360/30—Synthetic materials
    • B60B2360/36—Composite materials
    • B60B2360/368—Coproduced material combinations, e.g. By over-molding, co-extrusion, co-curing or vulcanizing
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B60B—VEHICLE WHEELS; CASTORS; AXLES FOR WHEELS OR CASTORS; INCREASING WHEEL ADHESION
    • B60B2900/00—Purpose of invention
    • B60B2900/10—Reduction of
    • B60B2900/111—Weight
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B60B—VEHICLE WHEELS; CASTORS; AXLES FOR WHEELS OR CASTORS; INCREASING WHEEL ADHESION
    • B60B2900/00—Purpose of invention
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    • B60B2900/112—Costs
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60Y—INDEXING SCHEME RELATING TO ASPECTS CROSS-CUTTING VEHICLE TECHNOLOGY
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    • B60Y2200/10—Road Vehicles
    • B60Y2200/13—Bicycles; Tricycles
    • B60Y2200/134—Racing bikes
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
    • Y02T10/00—Road transport of goods or passengers
    • Y02T10/80—Technologies aiming to reduce greenhouse gasses emissions common to all road transportation technologies
    • Y02T10/86—Optimisation of rolling resistance, e.g. weight reduction 

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Composite Materials (AREA)
  • Materials Engineering (AREA)
  • Moulding By Coating Moulds (AREA)

Description

碳纖維輪圈的製作方法及結構
本發明係一種碳纖維輪圈的製作方法及結構方面的技術領域，尤指一種具有提昇製作效率、降低失敗率及增加結構強度等功效之碳纖維輪圈的製作方法及結構者。
請參閱第1、2圖所示，一般習知的碳纖維輪圈主要為於一補強件13的外側包覆成型出斷面呈U形或呈倒三角形之一輪框10，再於該輪框10的外側面上黏貼結合有斷面呈H形之一輪胎固定座11而成者。該輪框10及該輪胎固定座11則主要係分別單獨利用複數預裁成長條片狀之碳纖維布12一片片交錯貼黏於如台灣公告第I434771號專利所示之模具及氣袋14上，然後進行加熱加壓之定型加工而成。
然而，在利用該碳纖維布12黏貼成型出該輪框10及該輪胎固定座11時，每一側面係皆至少需利用6至8片之碳纖維布12來交錯搭接，而且貼黏碳纖維布12之工作僅只能由人工來執行而無法由機械取代，所以欲完成一輪框10或一輪胎固定座11便需各自利用人工重複進行至少36次碳纖維布12的鋪貼動作，因此在製作上係非常的費時及費力而使製作效率非常低落，而且亦會使製作成本大幅增加。尤其是，每片碳纖維布12的碳纖維方向皆不 一致也不連續，而且整體結構在複數片碳纖維布12端部之相互搭接處係易使應力的傳遞產生不連續之情形，因此整體強度會因此大為降低。特別是，該複數片碳纖維布12相互交疊處係易產生較大、較多且不平均之間隙，所以在加熱加壓定型後，其之表面易殘存較多及較大的氣泡，致使失敗率因此大為提高。另外，利用分別單獨製作出該輪框10及該輪胎固定座11後，再將兩者貼黏結合之方式，不但會使製作過程較為繁複，而且亦會因其係非一體成型之結構，而使整體的結構強度因此大幅減弱。
另有一種習知的碳纖維輪圈之輪框及輪胎固定座之製作方法，如台灣公告第I382926號專利所示，其主要係利用兩梭子將具有相當寬度及塗設有膠之碳纖維帶纏繞在一環形芯軸上，再將其置入一模具中進行加熱加壓等成型作業而成。然而，由於該碳纖維帶係具有相當的寬度，因此其纏繞在該環形芯軸上，並經成型作業後，係易產生皺摺及較多且不均勻之氣泡，因此易有應力集中之情形，而使成品之製作不良率較高。
一般習知利用碳纖維布一片片貼合而成之碳纖維輪圈係存在著製作較為費時費力而製作效率低落、表面易殘存氣泡而使製作失敗率高及組成結構不連續而使整體結構強度不佳等之諸多問題。
本發明係提供一種碳纖維輪圈的製作方法，其之步驟包括：製備一上支撐件、將呈線狀之至少一股乾碳紗連續性且 傾斜一角度的纏繞於該上支撐件上，並纏繞數層以形成一輪胎固定座初胚、將一下支撐件設置於該輪胎固定座初胚的內側、將一補強件設置於該下支撐件的內側、將呈線狀之至少一股乾碳紗連續性且傾斜一角度的纏繞於該輪胎固定座初肧、該下支撐件及該補強件上，並纏繞數層以形成一外框、將纒繞有乾碳紗之輪胎固定座初胚、下支撐件及補強件置於一模具中進行定型作業以及於定型後之輪圈的外周面裁切出一開口並取出該上支撐件以完成該碳纖維輪圈之製作。其中，該上支撐件呈環狀且斷面製成與輪圈之輪胎固定座內側之溝槽相同的形狀。形成該輪胎固定座初胚之乾碳紗係由複數條細碳纖維紗集束而成，而且組成該輪胎固定座初胚之各層乾碳紗的繞設角度係不相同。該下支撐件係由耐熱質輕之材質製成，其係呈環狀且斷面設成與輪圈之輪框內部之框槽相同的形狀。該補強件係由耐熱質硬之材質製成，其係呈環狀且斷面呈倒三角形。該外框的上部係包覆於該輪胎固定座初胚的外側而形成一輪胎固定座，該外框的下部係包覆該下支撐件及該補強件的外側而形成一輪框。形成該外框之乾碳紗係由複數條細碳纖維紗集束而成，而且組成該外框之各層乾碳紗的繞設角度係不相同。在取出該上支撐件後係可使該輪胎固定座內部形成一溝槽。
本發明係提供一種碳纖維輪圈的結構，包括一輪胎固定座初胚、一下支撐件、一補強件及一外框。其中，該輪胎固定座初胚係由線狀之至少一股乾碳紗繞設數層後並進行定型作 業而製成，其係呈環狀且斷面概呈U字形，內部具有一溝槽，外側面具有由該溝槽貫通到外部之一開口。該下支撐件係由耐熱質輕之材質製成，其係呈環狀且斷面概呈外側大內側小之梯形，外側面係貼合於該輪胎固定座初胚的內側面，該補強件係由耐熱質硬之材質製成，其係呈環狀且斷面呈倒三角形，外側面貼合於該下支撐件的內側面。該外框係由線狀之至少一股乾碳紗繞設數層後並進行定型作業而成，其係呈環狀且上部包覆於該輪胎固定座初胚的外側面而形成一輪胎固定座，其之下部係包覆於該下支撐件及該補強件的外側而形成一輪框。
本發明所提供之碳纖維輪圈的製作方法及結構，其中由於該輪胎固定座初胚及該外框皆係由呈線狀之至少一股乾碳紗連續性繞設數層並經定型作業而成，因此係可易於利用機械進行該乾碳紗的繞設作業，所以係可大幅的節省製作人力及時間，而可提昇製作效率，而且並可降低製作成本。尤其是，由該乾碳紗連續性繞設並經定型作業後所形成之輪胎固定座初胚與外框所組成之輪圈，更是可避免應力傳遞不連續的情形發生，所以可使整體的結構強度大為提昇。特別是，利用該乾碳紗連續性繞設係可使各股乾碳紗之間的結構較為縝密，因此可使間隙較少、較小及較均勻，進而在經過置入模具、抽真空、注膠及加熱等定型作業後，係可減少氣泡的產生，故而可大幅降低製作失敗率。另外，該外框係一體包覆在該輪胎固定座初胚、下支撐件及該補強件的外側以使該輪胎固定座與輪框形成一體，因此係可進 一步提昇整體結構之強韌性。而且，亦無需再利用氣袋來幫助成型，所以係可減少氣袋之充氣、洩氣及開槽取出等之製作過程，故而可使其之製作更為簡單及快速。
[先前技術]
10‧‧‧輪框
11‧‧‧輪胎固定座
12‧‧‧碳纖維布
13‧‧‧補強件
14‧‧‧氣袋
[本發明]
20‧‧‧上支撐件
21‧‧‧輪胎固定座
22‧‧‧溝槽
23‧‧‧開口
30‧‧‧乾碳紗
31‧‧‧輪胎固定座初胚
32‧‧‧乾碳紗
33‧‧‧外框
40‧‧‧下支撐件
41‧‧‧輪框
42‧‧‧框槽
50‧‧‧補強件
第1圖係習知碳纖維輪圈之製作流程示意圖。
第2圖係習知碳纖維輪圈的貼合製作方式示意圖。
第3圖係本發明之輪胎固定座初胚的製作流程示意圖。
第4圖係本發明之輪框的製作流程示意圖。
第5圖係本發明之加熱加壓定型及切割成型的製作流程示意圖。
第6圖係本發明之製作流程的剖面示意圖。
第7圖係本發明之碳纖維輪圈結構的剖面放大示意圖。
請參閱第3~6圖所示，係顯示本發明所述之碳纖維輪圈的製作方法包括：製備一上支撐件20：該上支撐件20係由耐熱質硬之材質(如碳纖維複合材......等)製成，該上支撐件20呈環狀且斷面製成與輪圈之輪胎固定座21內側之溝槽22相同的形狀。
將呈線狀之至少一股乾碳紗30連續性的纏繞於該上支撐件20上：順著該上支撐件20的外周面連續性且傾斜一角度的繞設至少一股乾碳紗30，且於該上支撐件20上纒繞出將其包覆而具有適當厚度之乾碳紗30，並纏繞複數層以形成一輪胎固定座 初胚31，其中該乾碳紗30係由複數條細碳纖維紗集束而成，而且組成該輪胎固定座初胚31之各層乾碳紗30的繞設角度係不相同。
將一下支撐件40設置於該輪胎固定座初胚31的內側：該下支撐件40係由耐熱質輕之材質(如複合發泡材......等)製成，其係呈與上支撐件20同圓心之環狀，且斷面設成與輪圈之輪框41內部之框槽42相同的形狀，約概呈外側大內側小之梯形，且外側面貼合於該輪胎固定座初胚31的內側面。
將一補強件50設置於該下支撐件40的內側：該補強件50係由耐熱質硬之材質(如碳纖維複合材......等)製成，該補強件50係呈與該下支撐件40同圓心之環狀，且斷面呈倒三角形，其之外側面貼合於該下支撐件40的內側面，該倒三角形之內側角係形成圓弧導角。
將呈線狀之至少一股乾碳紗32連續性的纏繞於該輪胎固定座初肧31、該下支撐件40及該補強件50上：順著該輪胎固定座初肧31、該下支撐件40及該補強件50的外周面連續性且傾斜一角度的繞設至少一股乾碳紗32，使於該輪胎固定座初肧31、該下支撐件40及該補強件50上纒繞出將其包覆而具有適當厚度之複數層乾碳紗32，以形成連結成一體且未開設有溝槽22及開口23之輪胎固定座21與輪框41之一外框33，其中該乾碳紗32係由複數條細碳纖維紗集束而成，而且組成該外框33之各層乾碳紗32的繞設角度係不相同。
將纒繞有乾碳紗32之輪胎固定座初胚31、下支撐件 40及補強件50進行定型作業：將纒繞有乾碳紗32之輪胎固定座初胚31、下支撐件40及補強件50進行置入模具、抽真空、注膠及加熱等定型作業。
於定型後之輪圈的外周面裁切出一開口23並取出該上支撐件20：由該開口23取出該上支撐件20使該輪胎固定座21內部形成溝槽22，即完成該碳纖維輪圈之製作。
請再參閱第7圖所示，係顯示一種由上述製作方法製成之碳纖維輪圈的結構，其係指出該碳纖維輪圈的結構包括一輪胎固定座初胚31、一下支撐件40、一補強件50及一外框33，其中：該輪胎固定座初胚31係由複數層乾碳紗30繞設並經置入模具、抽真空、注膠及加熱等定型作業而成，其係呈環狀且斷面概呈U字形，內部具有一溝槽22，外側面具有由該溝槽22貫通到外部且寬度較小之一開口23，該乾碳紗30係由複數條細碳纖維紗集束而成。
該下支撐件40係由耐熱質輕之材質(如複合發泡材......等)製成，其係呈環狀且斷面概呈外側大內側小之梯形，外側面係貼合於該輪胎固定座初胚31的內側面。
該補強件50係由耐熱質硬之材質(如碳纖維複合材......等)製成，該補強件50係呈環狀且斷面呈倒三角形，其之外側面係貼合於該下支撐件40的內側面，該倒三角形之內側角係形成圓弧導角。
該外框33係由複數層乾碳紗32繞設並經過置入模具、抽真空、注膠及加熱等定型作業而成，其係呈環狀，且上部包覆於該輪胎固定座初胚31的外側面而形成一輪胎固定座21，其之下部係包覆於該下支撐件40及該補強件50的外側面而形成一輪框41，該乾碳紗32係由複數條細碳纖維紗集束而成。
本發明所提供之碳纖維輪圈的製作方法及結構，由於組成該輪圈之輪胎固定座初胚31及外框33皆係由呈線狀之至少一股乾碳紗30、32連續性繞設數層並經定型作業而成，因此係可利用機械進行乾碳紗30、32的繞設作業，所以可因此大幅的節省製作人力及時間，而可提昇製作效率，而且亦可降低製作成本。尤其是，由該乾碳紗30、32連續性繞設形成之輪胎固定座初胚31與外框33所組成之輪圈，更是可避免應力傳遞不連續的情形發生，所以可使整體的結構強度大為提昇。特別是，利用該乾碳紗30、32連續性繞設係可使各乾碳紗30、32之間的結構較為縝密，因此可使間隙較少、較小及較均勻，進而在經過置入模具、抽真空、注膠及加熱等定型作業後，係可減少氣泡的產生，故而可大幅降低製作失敗率。另外，該外框33係一體包覆在該輪胎固定座初胚31、該下支撐件40及該補強件的外側而使該輪胎固定座21與輪框41形成一體，因此可進一步提昇整體結構之強韌性。而且，亦可因此而無需再利用氣袋來幫助成型，所以係可減少氣袋之充氣、洩氣及開槽取出等之製作過程，故而可使其之製作更為簡單及快速。
20‧‧‧上支撐件
21‧‧‧輪胎固定座
22‧‧‧溝槽
23‧‧‧開口
31‧‧‧輪胎固定座初胚
33‧‧‧外框
40‧‧‧下支撐件
41‧‧‧輪框
42‧‧‧框槽
50‧‧‧補強件

Claims (9)

  1. 一種碳纖維輪圈的製作方法，包括：製備一上支撐件：該上支撐件係由耐熱質硬之材質製成，其係呈環狀且斷面製成與輪圈之輪胎固定座內側之溝槽相同的形狀；將呈線狀之至少一股乾碳紗連續性的纏繞於該上支撐件上：順著該上支撐件的外周面連續性且傾斜一角度的繞設至少一股乾碳紗，並繞設數層，使於該支撐件上纒繞出將其包覆而具有適當厚度之複數層乾碳紗以形成一輪胎固定座初胚，其中該乾碳紗係由複數條細碳纖維紗集束而成，而且各層之乾碳紗的繞設角度係不相同；將一下支撐件設置於該輪胎固定座初胚的內側：該下支撐件係由耐熱質輕的材質製成，其係呈環狀且斷面設成與輪圈之輪框內部之框槽相同的形狀，係概呈外側大內側小之梯形，並使該下支撐件的外側面貼合該輪胎固定座初胚的內側面；將一補強件設置於該下支撐件的內側：該補強件係由耐熱質硬之材質製成，其係呈環狀且斷面呈倒三角形，其之外側面係貼合於該下支撐件之內側面；將呈線狀之至少一股乾碳紗連續性的纏繞於該輪胎固定座初肧、該下支撐件及該補強件上：順著該輪胎固定座初肧、該下支撐件及該補強件的外周面連續性且傾斜一角度的繞設至少一股乾碳紗，並繞設數層，使於該輪胎固定座初肧、該下支撐件及該補強件上纒繞出將其包覆而具有適當厚度之複 數層乾碳紗，以形成連結成一體且未開設有溝槽之輪胎固定座與輪框之一外框，其中該乾碳紗係由複數條細碳纖維紗集束而成，形成該外框之各層乾碳紗的繞設角度係不相同；將纒繞有乾碳紗之輪胎固定座初胚、下支撐件及補強件進行定型作業：將纒繞有乾碳紗之輪胎固定座初胚、下支撐件及補強件進行置入模具、抽真空、注膠及加熱等定型作業；以及於定型後之輪圈的外周面裁切出一開口並取出該上支撐件：取出該上支撐件使該輪胎固定座內部形成一溝槽，即完成該碳纖維輪圈之製作。
  2. 如請求項1所述之碳纖維輪圈的製作方法，其中該上支撐件係為碳纖維複合材。
  3. 如請求項1所述之碳纖維輪圈的製作方法，其中該下支撐件的材質為複合發泡材。
  4. 如請求項1所述之碳纖維輪圈的製作方法，其中該補強件係為碳纖維複合材。
  5. 如請求項1所述之碳纖維輪圈的製作方法，其中該開口之寬度較該溝槽的寬度小。
  6. 一種碳纖維輪圈的結構，係包括：一輪胎固定座初胚，係由線狀之至少一股乾碳紗繞設數層後並經過定型作業而成，其係呈環狀且斷面概呈U字形，內部具有一溝槽，外側面具有由該溝槽貫通到外部之一開口，該乾碳紗係由複數條細碳纖維紗集束而成者；一下支撐件，係由耐熱質輕的材質製成，其係呈環狀且 斷面概呈外側大內側小之梯形，其之外側面係貼合於該輪胎固定座初胚的內側面；一補強件，係由耐熱質硬之材質製成，其係呈環狀且斷面呈倒三角形，其之外側面係貼合於該下支撐件之內側面；以及一外框，係由線狀之至少一股乾碳紗繞設數層後並經定型作業而成，其係呈環狀且上部包覆於該輪胎固定座初胚的外側面而形成一輪胎固定座，其之下部係包覆於該下支撐件及該補強件的外側面而形成一輪框，該乾碳紗係由複數條細碳纖維紗集束而成。
  7. 如請求項6所述之碳纖維輪圈的結構，其中該補強件係為碳纖維複合材，該下支撐件係為複合發泡材。
  8. 如請求項6所述之碳纖維輪圈的結構，其中該補強件之內側角係形成圓弧導角。
  9. 如請求項6所述之碳纖維輪圈的結構，其中製作該輪胎固定座初胚及該外框之定型作業係包含置入模具、抽真空、注膠及加熱等製程。
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