TWI744547B - 自行車曲柄的製造方法 - Google Patents
自行車曲柄的製造方法 Download PDFInfo
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- B29C70/28—Shaping operations therefor
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- B29C70/347—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core and shaping or impregnating by compression, i.e. combined with compressing after the lay-up operation combined with compressing after the winding of lay-ups having a non-circular cross-section, e.g. flat spiral windings
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- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
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Abstract
一種自行車曲柄的製造方法,包括:(a)提供一內框單元,(b)在該內框單元上纏繞一第一束單向連續纖維以形成一交叉圖樣,(c)將該交叉圖樣浸漬於一可固化樹脂材料以獲得一浸漬結構,及(d)將該浸漬結構在一模具中模製成型。
Description
本發明是有關於一種製造曲柄的方法,特別是指一種用於製造自行車的自行車曲柄的製造方法。
美國專利公開號2009/0236777A1揭露了一種製造自行車曲柄的方法,包括製備一預浸材料及一氣囊,熱壓該預浸材料及該氣囊,切割該預浸材料及該氣囊以形成二接合部以與二連接器接合,纏繞一碳纖維布,及加熱該預浸材料與由該碳纖維布包裹的該第一連接件及該第二連接件。
然而,傳統的自行車曲柄可能具有強度不足的問題。為了獲得一種具有更大強度的曲柄,該曲柄可藉由將多層複合材料(半固化片)纏繞在一中心件上,而後固化製成。在此種情況下,該自行車的曲柄重量會不理想地增加。
美國專利公開號2007/0186719及2008/0272572,以及歐洲專利公開號2921291A1也揭露了此種自行車的曲柄。
因此,本發明之目的,即在提供一種新穎的自行車曲柄的製造方法。透過這種新穎的製造方法,可以獲得一種輕質且高強度的自行車曲柄。
於是,本發明自行車曲柄的製造方法,包括以下步驟:
(a)提供一定義出一縱向軸線的內框單元,且該內框單元具有一第一座部、一第二座部、至少一第一方向反向引導件,及至少一第二方向反向引導件,該第二座部在一縱向軸線的方向上與該第一座部相間隔,該第一座部及該第二座部之間界定出一長形空間,該第一方向反向引導件形成在該第一座部或靠近該第一座部,該第二方向反向引導件形成在該第二座部或靠近該第二座部。
(b)將一第一束單向連續纖維穿過該第一方向反向引導件及該第二方向反向引導件來纏繞在該長形空間上,以在該內框單元上形成一交叉圖樣。
(c)將該交叉圖樣浸漬於一可固化樹脂材料以獲得一浸漬結構。
(d)在一模具中模製該浸漬結構以固化該可固化樹脂材料,從而獲得一用於自行車曲柄的纖維補強半成品。
本發明之功效在於:因為預備了該交叉圖樣,藉其所獲得的腳踏車曲柄強度即可提高,並且,該長形空間的存在能降低該腳踏車曲柄的重量,達到輕質化的效果。
參閱圖,本發明自行車曲柄6(見圖8)的製造方法的一第一實施例,包括步驟(a)至(d)。
在步驟(a)中,是提供一內框單元1。如圖1所示,該內框單元1定義了一縱向軸線L1,並具有一第一座部11、一第二座部12、一對橋接肋13、至少一第一方向反向引導件14,及至少一第二方向反向導引件15。在本第一實施例,該內框架單元1是由金屬材料製成。
該第二座部12在一縱向軸線L1的方向X上與該第一座部11相間隔。該第一座部11及該第二座部12之間界定出一長形空間130。
各個橋接肋13分別連接該第一座部11的一第一接合部111,及該第二座部12的一第二接合部121。該等橋接肋13在相對該縱向方向X的一橫向方向Y上彼此相間隔,使得該長形空間130進一步被該等橋接肋13界定。
該至少一第一方向反向引導件14形成在該第一座部11的其中一第一接合部111或其附近。該至少一第二方向反向引導件15形成在該第二座部12的其中一第二接合部121或其附近。在本第一實施例中,該內框架單元1的第一方向反向引導件14的數量為二,且分別形成在該第一座部11的該等第一接合部111,該第二方向反向引導件15的數量為二,且分別形成在該第二座部12的該等第二接合部121。如圖1所示,各個第一方向反向引導件14及各個第二方向反向引導件15皆是引導孔的形式,且是用於延伸一第一束單向連續纖維10,如下所述。
在步驟(b)中,如圖3所示,該第一束單向連續纖維10穿過該第一方向反向引導件14及該第二方向反向引導件15來纏繞在該長形空間130上,以繞該縱向軸線L1形成一交叉圖樣100。因為預備了該交叉圖樣100,藉其所獲得的腳踏車曲柄6強度即可提高。
該第一束單向連續纖維10可選自碳纖維或玻璃纖維。在本第一實施例中,該第一束單向連續纖維10是碳纖維,且可採用商用的碳纖維絲(Tairyfil carbon fiber TC42-12k, 台灣塑膠工業股份有限公司, 台灣)做為該第一束單向連續纖維10。
除此之外,在本第一實施例中,在步驟(b)之前,該製造方法還可進一步包括步驟(a1)。在步驟(a1)中,一泡綿狀構件2是適切地置入該長形空間130中,如圖2所示。該泡綿狀構件2可由任何合適的泡綿狀材料製成。
在步驟(c)中,一包含該交叉圖樣100的纖維層體300浸漬於一可固化樹脂材料4以獲得一浸漬結構400。如圖7所示,在步驟(c)之前,該纖維層體300與該內框單元1一起被設置於一模穴500內,該模穴500是由一模具5的一上模部51及一下模部52間彼此共同界定的。在步驟(c)中,一可固化樹脂材料4是透過一形成在該上模部51的注入管道510注入到該模穴500中,以便允許該纖維層體300浸漬於該可固化樹脂材料4,藉此獲得該浸漬結構400。
在本第一實施例中,該纖維層體300更包含一第一纖維編織套31、一螺旋圖樣200,及一第二纖維編織套32(見圖4至圖6),且在步驟(c)之前,該製造方法還包括步驟(b1)、(b2),及(b3)。
在步驟(b1)中,如圖4所示,該內框單元1被該第一纖維編織套31覆蓋,以允許該第一纖維編織套31疊置在該交叉圖樣100上面,如圖3所示。該第一纖維編織套31可由碳纖維或玻璃纖維製成。在本第一實施例中,該第一纖維編織套31是由碳纖維製成,且可採用商用碳纖維編織套(3k-T300, 台麗, 日本)做為該第一纖維編織套31。
在其他實施態樣中,為了更進一步增強該腳踏車曲柄6的強度,可以再加上另一纖維編織套(圖未示)來覆蓋該第一纖維編織套31。
在步驟(b2)中,如圖5所示,將一第二束單向連續纖維20螺旋地圍繞該縱向軸線L1纏繞在該第一纖維編織套31上以形成該螺旋圖樣200。該第二束單向連續纖維20可採用與該第一束單向連續纖維10相同的材料製成。
在步驟(b3)中,如圖6所示,該螺旋圖樣200被該第二纖維編織套32疊置於其上。在其後,於步驟(c)之前,將該第二纖維編織套32的每一端繫結成結。該第二纖維編織套32可採用與該第一纖維編織套31相同的材料製成。
因此,在該實施例的步驟(c)中,該第一纖維編織套31、該第二纖維編織套32及該螺旋圖樣200即與該交叉圖樣100一起浸漬於該可固化樹脂材料4。
在步驟(d)中,該浸漬結構400被模製在該模具5中以固化該可固化樹脂材料4,從而獲得一用於自行車曲柄6的纖維補強半成品(圖未示)。
該纖維補強半成品可以通過習知的方法續行處理,以允許如圖8所示的自行車曲柄6來具有二連接插設件61,62,該等連接插設件61,62是分別用來連接一腳踏車的中央支架(圖未示)及一踏板(圖未示)。或者,該等連接插設件61,62可與該浸漬結構400共同模製。
參閱圖9,說明本發明自行車曲柄的製造方法的一第二實施例的內框單元1。該內框單元1與該第一實施例類似,差異在於該內框單元1不包括該等橋接肋13(見圖1),除此之外,步驟(a1)被步驟(a2)及(a3)替代。
在步驟(a2)中,提供一具有二端部211,212的長形泡綿狀構件21。該等端部211,212被配置為能分別與該第一座部11及該第二座部12緊密配合,以允許該長形泡綿狀構件21適切地設置在該第一座部11及該第二座部12之間的該長形空間130。
在步驟(a3)中,該長形泡綿狀構件21設置在該長形空間130中,以允許該長形泡綿狀構件21的該等端部211,212分別與該第一座部11及該第二座部12緊密配合。
惟以上所述者,僅為本發明之實施例而已,當不能以此限定本發明實施之範圍,凡是依本發明申請專利範圍及專利說明書內容所作之簡單的等效變化與修飾,皆仍屬本發明專利涵蓋之範圍內。
1‧‧‧內框單元10‧‧‧第一束單向連續纖維100‧‧‧交叉圖樣11‧‧‧第一座部111‧‧‧第一接合部12‧‧‧第二座部121‧‧‧第二接合部13‧‧‧橋接肋130‧‧‧長形空間14‧‧‧第一方向反向導引件15‧‧‧第二方向反向導引件2‧‧‧泡綿狀構件20‧‧‧第二束單向連續纖維200‧‧‧螺旋圖樣21‧‧‧長形泡綿狀構件211,212‧‧‧端部300‧‧‧纖維層體31‧‧‧第一纖維編織套32‧‧‧第二纖維編織套4‧‧‧可固化樹脂材料400‧‧‧浸漬結構5‧‧‧模具500‧‧‧模穴51‧‧‧上模部510‧‧‧注入管道52‧‧‧下模部6‧‧‧腳踏車曲柄61,62‧‧‧連接插設件L1‧‧‧縱向軸線X,Y‧‧‧方向
本發明之其他的特徵及功效,將於參照圖式的實施方式中清楚地呈現,其中: 圖1是一俯視示意圖,說明本發明自行車曲柄的製造方法的第一實施例的一內框單元; 圖2一類似於圖1的視圖,說明該第一實施例的一泡綿狀構件適切地置入該內框單元的一長形空間; 圖3是一示意圖,說明該第一實施例中圍繞該內框單元的一縱向軸線所形成的一交叉圖樣; 圖4是一示意圖,說明該第一實施例的一第一纖維編織套覆蓋該內框單元; 圖5是一示意圖,說明該第一實施例的一螺旋圖樣是形成在該第一纖維編織套上; 圖6是一示意圖,說明該第一實施例的一第二纖維編織套覆蓋在圖5所示的該螺旋圖樣; 圖7是一剖視示意圖,說明該第一實施例的一浸漬結構設置在一模具中; 圖8是一示意圖,說明該第一實施例的一自行車曲柄;及 圖9是一俯視示意圖,說明本發明自行車曲柄的製造方法的第二實施例的一內框單元,其中一長形泡綿狀構件設置在該內框單元的一第一座部及一第二座部之間。
1‧‧‧內框單元
11‧‧‧第一座部
111‧‧‧第一接合部
12‧‧‧第二座部
121‧‧‧第二接合部
130‧‧‧長形空間
14‧‧‧第一方向反向導引件
15‧‧‧第二方向反向導引件
L1‧‧‧縱向軸線
X,Y‧‧‧方向
13‧‧‧橋接肋
Claims (5)
- 一種自行車曲柄的製造方法,包括以下步驟:(a)提供一定義出一縱向軸線的內框單元,且該內框單元具有一第一座部、一第二座部、至少一第一方向反向引導件、至少一第二方向反向引導件,及一對橋接肋,該第二座部在一縱向軸線的方向上與該第一座部相間隔,該第一座部具有至少一第一接合部,該第二座部具有至少一第二接合部,該至少一第一方向反向引導件是引導孔的形式,形成在該第一座部的至少一第一接合部或靠近該第一座部,該第二方向反向引導件是引導孔的形式,形成在該第二座部的至少一第二接合部或靠近該第二座部,各個橋接肋分別連接該至少一第一接合部及該至少一第二接合部,該等橋接肋在相對該縱向方向的橫向方向上彼此相間隔,且與該第一座部及該第二座部之間界定出一鏤空的長形空間;(b)將一第一束單向連續纖維穿過該至少一第一方向反向引導件及該至少一第二方向反向引導件來纏繞在該長形空間上,以在該內框單元上形成一交叉圖樣;(c)用一第一纖維編織套罩覆該內框單元,以允許該第一纖維編織套覆蓋在該交叉圖樣上;(d)將該第一纖維編織套與該交叉圖樣浸漬於一可固化樹脂材料以獲得一浸漬結構;及(d)在一模具中模製該浸漬結構以固化該可固化樹脂材料,從而獲得一用於自行車曲柄的纖維補強半成品。
- 如請求項1所述的自行車曲柄的製造方法,其中,在步驟(b)之前還包括:步驟(a1)將一泡綿狀構件適切地置入該長形空間中。
- 如請求項1所述的自行車曲柄的製造方法,其中,在步驟(d)之前還包括:步驟(c1)將一第二束單向連續纖維螺旋地圍繞該縱向軸線纏繞在該第一纖維編織套上以形成一螺旋圖樣;及步驟(c2)用一第二纖維編織套覆蓋該螺旋圖樣,從而允許該第二纖維編織套及該螺旋圖樣與該交叉圖樣及該第一纖維編織套在步驟(c)一起浸漬於該可固化樹脂材料。
- 如請求項3所述的自行車曲柄的製造方法,其中,該第一束單向連續纖維及該第二束單向連續纖維是碳纖維,並且該第一纖維編織套及該第二纖維編織套由碳纖維製成。
- 如請求項1所述的自行車曲柄的製造方法,其中,該至少一第一方向反向引導件形成在該第一座部,且該至少一第二方向反向引導件形成在該第二座部,該製造方法在步驟(b)之前還包括以下步驟:(a2)提供一具有二端部的長形泡綿狀構件,該等端部配置為能分別與該第一座部及該第二座部緊密配合,以允許該長形泡綿狀構件適切地設置在該長形空間中的該第一座部及該第二座部之間;及(a3)將該長形泡綿狀構件設置在該長形空間中,以使該長形泡綿狀構件的該等端部分別與該第一座部及該第二座部緊密配合。
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CN112388992A (zh) * | 2019-08-14 | 2021-02-23 | 林展奕 | 自行车曲柄制程 |
US20220250711A1 (en) * | 2020-11-20 | 2022-08-11 | Fox Factory, Inc. | Insert undercut |
DE202022103016U1 (de) | 2022-05-29 | 2023-08-31 | Igus Gmbh | Tretkurbel, insbesondere Fahrradtretkurbel, mit Kurbelarmköper aus Kunststoff |
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US2921291A (en) * | 1955-03-09 | 1960-01-12 | Muzak Corp | Automatic control circuit |
EP0270388B1 (fr) * | 1986-10-31 | 1990-07-18 | Look Sté. | Manivelle pour pédalier de bicyclette |
US5435869A (en) * | 1993-08-27 | 1995-07-25 | Christensen; Roland | Method for manufacturing a composite crank arm |
US5632940A (en) * | 1994-03-29 | 1997-05-27 | Whatley; Bradford L. | Method of making an integrally stiffened article |
CA2401028C (en) * | 2000-03-03 | 2006-10-31 | Proteus Gmbh | Component consisting of a fibre-reinforced synthetic material and a method for producing same |
CN2425848Y (zh) * | 2000-05-12 | 2001-04-04 | 林珍妮 | 自行车曲柄 |
CN2509074Y (zh) * | 2001-08-13 | 2002-09-04 | 明安国际企业股份有限公司 | 高分子复合材料的自行车空心曲柄 |
EP1818251A1 (en) * | 2006-02-14 | 2007-08-15 | CAMPAGNOLO S.r.l. | Bicycle pedal crank, intermediate product and method for manufacturing such a pedal crank |
TW200829472A (en) | 2007-01-11 | 2008-07-16 | Brainco Composites Inc | Bike crank shaft made of rib-structural carbon fiber and method of making the same |
US20080272572A1 (en) | 2007-05-04 | 2008-11-06 | Carlos Tsai | Composite Carbon Fiber Bicycle Crank and Its Method of manufacture |
US20090236777A1 (en) | 2007-06-13 | 2009-09-24 | Douglas Chiang | Method for Manufacturing Bicycle Crank |
CN202670040U (zh) * | 2012-07-23 | 2013-01-16 | 唐山金亨通车料有限公司 | 一种高强度碳纤维自行车空心曲柄 |
CN102887199B (zh) * | 2012-09-29 | 2014-02-26 | 张卫兵 | 一种碳纤维自行车曲柄及其制造工艺 |
DE102014103701B3 (de) * | 2014-03-18 | 2015-05-21 | Holger Faupel | Kurbelarm für ein Fahrrad-Tretkurbelsystem und Herstellungsverfahren dafür |
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US10603852B2 (en) | 2020-03-31 |
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