TWM576098U - Bicycle frame component with thermoplastic composite material - Google Patents

Abstract

The present invention is a bicycle thermoplastic composite frame member, the frame member comprising two or more shell members thermoformed by a thermoplastic composite material, each shell member comprising an outer surface on the outer side, The shell groove formed by the shell surrounding, and at least two abutting side edges for joining and joining the shell members, the corresponding mating side edges of the shell members are alternately overlapped and welded to form an integrally joined weld zone. The novel frame member is a shell member which is pre-formed by two or more thermoplastic composite materials, and is formed by cohesive fusion welding, which can stabilize the forming quality of the composite frame member, and has the advantages of light weight and structure. Excellent characteristics such as strength.

Description

Bicycle thermoplastic composite frame parts

The invention relates to a molding technology of a bicycle frame part, in particular to a bicycle thermoplastic composite frame structure formed by thermocompression bonding using a thermoplastic composite material.

The bicycle frame member made of a carbon fiber composite material is generally manufactured by using a frame member disclosed in the patent documents such as the publications CN1143010A, CN101786329A, and CN102729484A, mainly using a foam material or an air bag to form a core mold. Then, a preform of the thermosetting carbon fiber prepreg is laminated on the core mold to form a preform, and then the laminated preform is placed in a molding die to be heated and pressed to be solidified, and then the molding die is opened and the carbon fiber shell layer is placed. The inner core mold is taken out to complete the demoulding, and finally the detailed finishing process is performed to produce the finished product of the carbon fiber frame member.

The existing frame members made of thermosetting carbon fiber are easy to be insufficient or uneven due to the strength of the compression support of the mandrel, resulting in unstable surface quality and structural strength of the formed frame member, and after the frame member is formed, the car is formed. The shape of the frame member can no longer be changed by heating, and cannot be repaired and recycled, which results in considerable restrictions on the implementation of the existing composite frame member.

The existing carbon fiber frame forming method can be molded at one time by using a molding die, but it is limited by the molding temperature and pressure of the thermosetting carbon fiber and the resin, and the molding time takes about 50 minutes to 60 minutes, and the molding time is quite long. High cost and not suitable for mass production. If the existing molding method is to meet the demand for mass production, it is necessary to prepare a plurality of sets of molding dies and operators to work at the same time, resulting in the cost of the mold and labor costs.

In order to solve the problem that the quality of the thermoset carbon fiber frame parts of the existing bicycle is unstable and difficult to repair and recycle, the present invention proposes a bicycle thermoplastic composite frame member, and the novel is preformed by two or more preforms. The thermoplastic composite shell part is combined with the hot-press welding joint molding, which can make the structure of the frame member strong and stable in forming quality, and can be repaired and recycled, effectively solving the problems existing in the prior art.

The present invention solves the technical problem and provides a bicycle thermoplastic composite frame member, which comprises two or more shell members which are thermoformed and can be combined with a thermoplastic composite material, and each shell member includes an outer surface on the outer side. a shell groove formed by the shell and at least two abutting side edges for mutually joining and joining the shell members, wherein the corresponding mating side edges of the shell members are alternately overlapped and welded to form an integrally joined weld Area.

Preferably, the welding zone has a fusion convex body having a thickness larger than that of the shell member and having a thickened shape.

Preferably, the thermoplastic composite material is a thermoplastic carbon fiber material or a thermoplastic glass fiber material.

Preferably, the frame member is composed of two shell members that can be combined with each other.

Compared with the prior art, the enhancements obtained by the technical means proposed by the present invention include: 1. The frame member of the present invention is composed of two or more shell members pre-formed with a thermoplastic composite material, and is welded and welded. The joint molding can stabilize the molding quality of the composite frame member, and has excellent characteristics such as light weight and structural strength. 2. The new type of thermoplastic composite sheet is first formed by hot pressing of a mold to form two or more closable shell parts, and then the shell parts are combined by hot pressing and welding to form a complete frame member. It usually takes about 5 minutes of molding time and can save labor costs. It is very suitable for mass production and has high value mass production. 3. The new frame structure is made of thermoplastic composite material. The thermoplastic composite material is an environmentally-friendly material that can be repeatedly heated and molded. It can be easily repaired, recycled and reused, and meets modern environmental protection requirements.

The molding method of the bicycle thermoplastic composite composite frame member proposed by the present invention mainly comprises the steps of: forming a shell member, a step of combining the shell parts, a step of forming a mold by hot pressing, and a step of removing the inner support member. Referring to FIG. 1 to FIG. 5, the present invention is described as a first preferred embodiment of a three-pronged member of a bicycle frame, wherein:

Shell molding step: As shown in FIG. 1 and FIG. 5, the present invention disassembles a pre-formed frame member 20 into two tangible shell members 20A and shell members 20B in a right and left split manner, and forms the shell member. In the step, the thermoplastic composite sheet 10 made of a thermoplastic carbon fiber material or a thermoplastic glass fiber material is selected, and the thermoplastic composite sheet is prepared by hot pressing forming of the mold together with appropriate trimming means. 10 is hot pressed to form the shell member 20A and the shell member 20B. As shown in FIG. 2, each of the shell member 20A and the shell member 20B includes an outer surface 21 on the outer side, a shell groove 22 formed by the shell member 20A and the shell member 20B, and at least two passages for the shell. The abutting side edge 23 of the piece 20A and the shell member 20B are coupled to each other. In the embodiment shown in the figure, in order to allow the abutting side edges 23 of the case member 20A and the case member 20B to be alternately overlapped, the respective case members 20A The side edge of the abutting side edge 23 of the shell member 20B may exceed the width of the halve of the frame member 20 by about 2.5 mm to 6 mm, so that the shell member 20A and the shell member 20B are opposite each other. The abutting side edge 23 can have an overlapping area having a width of approximately 5 mm to 12 mm. In other embodiments, the present invention can split the prefabricated frame member into three or more shell members that can be coupled to each other. The present invention does not specifically limit the number of split shell members.

The shell member is combined and assembled. As shown in FIG. 2 and FIG. 3, the shell member 20A and the shell member 20B are butt-joined, and the corresponding butt-side edges 23 of the shell member 20A and the shell member 20B are alternately overlapped. In the embodiment shown, the overlapping area of the corresponding abutting side edges 23 has a width of approximately 8 mm. And in the subsequent hot press forming step of the mold, the inside of the shell member 20A and the shell member 20B can obtain sufficient support. The present invention is provided with an inner support member 30 when the shell member 20A and the shell member 20B are butt-joined. The inner support member 30 may be any suitable supporting member such as a metal core mold, a foam core mold, a wax core mold or an air bag. The present invention is not particularly limited. In the embodiment shown in the figure, the The inner support member 30 is a metal core mold, and the inner support member 30 can be smoothly removed in a subsequent step. The inner support member 30 is composed of a middle mold member 31, an upper mold member 32 and a lower mold member 33. And the inner support member 30 is oppositely disposed with a retaining edge 34 at an overlapping region corresponding to each of the butting side edges 23.

The mold hot press forming step: as shown in FIG. 3 and FIG. 4, the mating of the shell member 20A and the shell member 20B by the hot pressing forming of the mold, with the support or pressurization of the inner support member 30. The overlap region of the side edges 23 is thermocompression-bonded to form a welded joint portion 24, and the shell member 20A and the shell member 20B are joined to form the frame member 20; wherein the docking in the embodiment The overlapping regions of the side edges 23 will match the corresponding recessed edges 34 to form a thickened form of the welded projections 241, further enhancing the structural strength of the welded portion 24 of the frame member 20.

Step of removing the inner support member: as shown in FIG. 4 and FIG. 5, after the hot press forming step of the mold is completed, the inner support member 30 located inside the frame member 20 is removed. In this embodiment, the removal step is first. The middle mold member 31 is taken out, and the upper mold member 32 and the lower mold member 33 are sequentially taken out, and the step of removing the inner support member 30 is successfully completed, and the appropriate trimming trimming means can be used to complete the drawing. The finished product of the frame member 20 shown in FIG.

The molding method of the thermoplastic composite material frame member of the present invention firstly forms a pair of closable shell members 20A and shell members 20B by hot pressing of the thermoplastic composite sheet, and then presses the shell member by hot pressing of the mold. 20A, the shell member 20B is welded and joined to form a complete composite frame member 20, and the whole molding time is fast, usually only takes about 5 minutes of molding time, compared with about 50 pieces of the existing thermosetting carbon fiber frame member. From minutes to 60 minutes of molding time, the new model has increased the molding speed by more than 10 times and can save labor costs. It is very suitable for mass production and has great industrial value.

As shown in FIG. 2 and FIG. 5, the thermoplastic composite frame member 20 of the present invention comprises two shell members 20A and a shell member 20B which are thermoformed and joined together by a thermoplastic composite material, and the shell member 20A is Each of the portions of the case member 20B that are joined to each other forms a fusion-welded region 241 that is welded together. The present invention firstly heat-compresses the thermoplastic composite into the shell member 20A and the shell member 20B, and then joins the heat-pressure welded joint to form a stable quality of the composite frame member 20, and has the characteristics of light weight and strong structure. At the same time, the thermoplastic composite material can be used to repeatedly heat the molding characteristics, which can be easily repaired and recycled, and meets current environmental requirements.

Referring to the second preferred embodiment shown in FIG. 6, the shell member 40A and the shell member 40B in the embodiment each have an outer surface 41, a shell groove 42, and at least two abutting side edges 43, each phase. Corresponding butted side edges 43 are provided with matching stepped engaging faces, so that the abutting side edges 43 of the shell member 40A and the shell member 40B are matched and overlapped by a stepped engaging surface, and the inner supporting member 30A is not provided with a seat. In the manner of the concave edge, the opposite abutting side edges 43 of the case member 40A and the case member 40B are thermocompression-bonded and integrally joined.

Referring to the third preferred embodiment shown in FIG. 7 and FIG. 8 , the present invention is an embodiment of a bicycle front fork. The frame member 50 of the present embodiment is split into two detachable shell members in a front-rear manner. 50A, the shell member 50B, and at least two abutting side edges 51 for the shell member 50A and the shell member 50B to be coupled to each other, and the shell member 50A and the shell member are respectively provided on the shell member 50A and the shell member 50B. Each of the butting side edges 51 of the 50B is coupled to the heat-welded and welded joint 52, and is coupled with the two fork members 53, 54 to form a vehicle structure for use as a bicycle front fork as shown in FIG. Item 50.

Referring to the fourth preferred embodiment shown in FIG. 9 and FIG. 10, the present invention is an embodiment of the entire bicycle. The embodiment includes a frame member 60 as a front triangle of the frame and a vehicle structure as a rear fork. The member 70 and the frame member 80 and the like as the lower fork; the frame member 60 is split into two tangible shell members 60A and 60B in a left-right split manner, and the frame member 70 is The above-mentioned manner is disassembled into two shell members 70A and 70B which can be combined with each other. The frame member 80 is also disassembled into two detachable shell members 80A and shell members 80B in the above manner, and the shell members 80A are respectively The shell member 60B, the shell member 70A, the shell member 70B, the shell member 80A, and the shell member 80B are each provided with at least two passages for the two corresponding shell members 60A, the shell member 60B, the shell member 70A, the shell member 70B, and the shell member. The abutting side edge 61, the butting side edge 71, and the butting side edge 81 of the piece 80A and the shell member 80B are respectively coupled to each other, and the corresponding two shell members 60A, the shell member 60B, the shell member 70A, the shell member 70B, and the shell member 80A. The abutting side edges 61, the butting side edges 71, and the butting side edges 81 of the shell member 80B are integrally joined by heat and pressure welding, wherein the butting side edges 61 are combined with heat. The welded portion 62 is welded together, and is assembled with the assembly members 60, the frame member 70, and the frame member 80 to form a frame member 60, a frame member 70, and a vehicle structure as shown in FIG. The bicycle frame of item 80.

The above detailed description provides those skilled in the art to understand the technical content of the present invention, and is not intended to limit the present invention. The equivalent embodiment of the present invention is modified or modified. , are still within the scope of protection of this new type.

10‧‧‧ thermoplastic composite sheet

20‧‧‧Car frame parts

20A, 20B‧‧‧ shell parts

21‧‧‧ outer surface

22‧‧‧ Shell

23‧‧‧Docking side edges

24‧‧‧welding area

241‧‧‧fused bump

30, 30A‧‧‧ inner support

31‧‧‧Medium modules

32‧‧‧Upper module

33‧‧‧Down module

34‧‧‧Let the margin

40A, 40B‧‧‧ shell parts

41‧‧‧ outer surface

42‧‧‧ shell

43‧‧‧Docking side edges

50, 60, 70, 80‧‧‧ car frame parts

50A, 50B, 60A, 60B, 70A, 70B, 80A, 80B‧‧‧ shell parts

51, 61, 71, 81‧‧‧ docking side edges

52, 62‧‧‧ welding area

53, 54‧‧‧ fork head pieces

BRIEF DESCRIPTION OF THE DRAWINGS Figure 1 is an exploded view of a first preferred embodiment of the present invention in which a thermoplastic composite sheet is hot pressed to form a shell member. 2 is an exploded perspective view showing two shell members and a core mold of the first preferred embodiment (three-pronged member) of the present invention. 3 is a schematic cross-sectional view showing a structure in which two shell members and a core mold are combined and assembled before thermocompression bonding according to the first preferred embodiment of the present invention. 4 is a schematic cross-sectional view showing the structure of the frame member after the thermocompression bonding of the first preferred embodiment of the present invention. Figure 5 is a perspective view of the finished frame of the first preferred embodiment of the present invention. Figure 6 is a schematic cross-sectional view showing the structure of the second preferred embodiment of the second preferred embodiment of the present invention in which two shell members and a core mold are combined before thermocompression bonding. Figure 7 is an exploded perspective view of two shell members of the third preferred embodiment (front fork) of the present invention. Figure 8 is a perspective view of the finished part of the frame member of the third preferred embodiment of the present invention. Figure 9 is an exploded perspective view showing the constituent shell member of the fourth preferred embodiment (the entire frame) of the present invention. Figure 10 is a perspective view of the finished article of the fourth preferred embodiment of the present invention.

Claims (9)

A bicycle thermoplastic composite frame member, the frame member comprising two or more shell members which are thermoformed and can be combined with a thermoplastic composite material, each shell member comprising an outer surface on the outer side, and a shell member The shell groove formed by the surrounding and the at least two abutting side edges for mutually engaging and joining the shell members, the corresponding abutting side edges of the shell members are alternately overlapped and welded to form an integrally joined weld zone. The bicycle thermoplastic composite frame member according to claim 2, wherein the welding zone has a fusion convex body having a thickness thicker than the thickness of the casing member. The bicycle thermoplastic composite frame member according to claim 1 or 2, wherein the thermoplastic composite material is a thermoplastic carbon fiber material or a thermoplastic glass fiber material. The bicycle thermoplastic composite frame member according to claim 3, wherein the frame member is composed of two shell members that can be opposed to each other. A bicycle thermoplastic composite frame member according to claim 4, wherein the frame member is a three-prong member of the bicycle frame. The bicycle thermoplastic composite frame member of claim 4, wherein the frame member is a bicycle front fork. The bicycle thermoplastic composite frame member according to claim 4, wherein the frame member is a front triangle of the frame. The bicycle thermoplastic composite frame member of claim 4, wherein the frame member is a rear upper fork. The bicycle thermoplastic composite frame member according to claim 4, wherein the frame member is a rear lower fork.