WO2020124538A1 - 自行车热塑复合材车架构件的成型方法及其成品 - Google Patents

自行车热塑复合材车架构件的成型方法及其成品 Download PDF

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Publication number
WO2020124538A1
WO2020124538A1 PCT/CN2018/122595 CN2018122595W WO2020124538A1 WO 2020124538 A1 WO2020124538 A1 WO 2020124538A1 CN 2018122595 W CN2018122595 W CN 2018122595W WO 2020124538 A1 WO2020124538 A1 WO 2020124538A1
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WIPO (PCT)
Prior art keywords
shell
thermoplastic composite
bicycle
frame member
forming
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Application number
PCT/CN2018/122595
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English (en)
French (fr)
Inventor
胡绍荣
刘柳正
Original Assignee
太宇工业股份有限公司
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
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Publication date
Application filed by 太宇工业股份有限公司 filed Critical 太宇工业股份有限公司
Priority to CN201880098023.7A priority Critical patent/CN112805214A/zh
Priority to PCT/CN2018/122595 priority patent/WO2020124538A1/zh
Publication of WO2020124538A1 publication Critical patent/WO2020124538A1/zh
Priority to US17/333,774 priority patent/US20210284269A1/en
Priority to US18/360,226 priority patent/US20230373175A1/en

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
    • B62K—CYCLES; CYCLE FRAMES; CYCLE STEERING DEVICES; RIDER-OPERATED TERMINAL CONTROLS SPECIALLY ADAPTED FOR CYCLES; CYCLE AXLE SUSPENSIONS; CYCLE SIDE-CARS, FORECARS, OR THE LIKE
    • B62K3/00—Bicycles
    • B62K3/02—Frames
    • B62K3/06—Frames of open type
    • 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
    • B29C70/462—Moulding structures having an axis of symmetry or at least one channel, e.g. tubular structures, frames
    • 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
    • B29C70/465—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 by melting a solid material, e.g. sheets, powders of fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
    • B62K—CYCLES; CYCLE FRAMES; CYCLE STEERING DEVICES; RIDER-OPERATED TERMINAL CONTROLS SPECIALLY ADAPTED FOR CYCLES; CYCLE AXLE SUSPENSIONS; CYCLE SIDE-CARS, FORECARS, OR THE LIKE
    • B62K19/00—Cycle frames
    • B62K19/02—Cycle frames characterised by material or cross-section of frame members
    • B62K19/16—Cycle frames characterised by material or cross-section of frame members the material being wholly or mainly of plastics
    • 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
    • B29K2101/12—Thermoplastic materials
    • 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
    • B29L2031/30—Vehicles, e.g. ships or aircraft, or body parts thereof
    • B29L2031/3091—Bicycles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
    • B62K—CYCLES; CYCLE FRAMES; CYCLE STEERING DEVICES; RIDER-OPERATED TERMINAL CONTROLS SPECIALLY ADAPTED FOR CYCLES; CYCLE AXLE SUSPENSIONS; CYCLE SIDE-CARS, FORECARS, OR THE LIKE
    • B62K21/00—Steering devices
    • B62K21/02—Front wheel forks or equivalent, e.g. single tine
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
    • B62K—CYCLES; CYCLE FRAMES; CYCLE STEERING DEVICES; RIDER-OPERATED TERMINAL CONTROLS SPECIALLY ADAPTED FOR CYCLES; CYCLE AXLE SUSPENSIONS; CYCLE SIDE-CARS, FORECARS, OR THE LIKE
    • B62K3/00—Bicycles
    • B62K3/02—Frames
    • B62K3/04—Frames having a substantially horizontal top bar

Definitions

  • the invention relates to a molding technology of a bicycle frame member, in particular to a molding method and a finished product of a bicycle thermoplastic composite frame member formed by using a thermoplastic composite material in a thermocompression bonding manner.
  • the existing carbon fiber car frame molding method although it can be molded at one time using a molding die, is limited by the molding temperature and pressure of the thermosetting carbon fiber and resin.
  • the molding time takes about 50 minutes to 60 minutes, and the molding time is quite long And the cost is high, not suitable for mass production. If the existing molding method is to meet the demand for mass production, multiple sets of molding molds must be prepared and the operators work at the same time, resulting in the consumption of mold costs and labor costs.
  • the present invention proposes a method for forming a bicycle thermoplastic composite frame member.
  • the plastic composite sheet is hot-pressed by a mold to form two or more shell parts that can be joined together, and then the shell parts are joined by hot-pressing and welding to form a complete vehicle frame part, and the thermoplastic composite material is quickly.
  • the car frame components are made and shaped, which is very suitable for mass production and manufacturing, and effectively solves the problems in the existing technology.
  • the present invention provides a bicycle thermoplastic composite frame component.
  • the present invention is based on two or more The pre-formed thermoplastic composite shell parts are joined together by thermocompression welding to form, which can make the structure of the car frame strong and the molding quality stable, and can be repaired and recycled to effectively solve the problems in the existing technology.
  • the present invention solves the technical problem and proposes a method for forming a bicycle thermoplastic composite frame member, including:
  • Shell forming step hot pressing the thermoplastic composite sheet with a mold to form two or more shells that can be joined together, each shell includes an outer surface, a shell groove formed by the shell and at least two Let the shell parts be relatively joined to the butt edge of the joint;
  • Step for butting and combining the shell parts butting and combining the shell parts, so that the corresponding butt edges of the shell parts are staggered and overlapped, and an inner support part capable of forming support for the shell parts is provided in the interior surrounded by the shell parts ;
  • Mold hot press forming step using mold hot press forming, the overlapping areas of the butt side edges where the shells are relatively joined are formed by hot press welding to form an integrated welding area, and the shells are joined to form a frame member;
  • Step of removing the inner support member remove the inner support member inside the vehicle frame member, and use trimming and trimming means to make the finished product of the vehicle frame member.
  • the thermoplastic composite sheet is a thermoplastic carbon fiber sheet or a thermoplastic glass fiber sheet.
  • the frame member includes two shell members that can be opposed to each other.
  • the welding area forms a thickened welding protrusion.
  • the inner support member is provided with a yielding concave edge at a position corresponding to the overlapping area of the butting side edges, and the welding area forms the welding convex body matching the yielding concave edge.
  • the inner support is a metal core mold and includes a middle mold, an upper mold, and a lower mold.
  • the butted side edges of the butting joints form a staggered overlapping with matching stepped joint surfaces.
  • the invention solves the technical problem and proposes a bicycle thermoplastic composite material frame component.
  • the bicycle thermoplastic composite material frame component includes two or more shell components which are formed by thermocompression molding of the thermoplastic composite material and can be relatively closed.
  • Each shell component includes Has an outer surface on the outer side, a shell groove formed by the shell members, and at least two butt side edges for the shell members to be relatively joined and connected, and the corresponding butt side edges of the shell members are alternately overlapped with each other And the welding forms an integrally connected welding area.
  • the welding area has a welding protrusion with a thicker shape than the thickness of the shell.
  • the enhancements in the technical means provided by the present invention include:
  • thermoplastic composite sheet is first hot-pressed with a mold to form two or more shell parts that can be joined together, and then the two or more shell parts are joined by thermocompression welding to form a complete vehicle frame part.
  • the invention is quick to form, usually only takes about 5 minutes to form, and can save labor costs. It is very suitable for mass production and has high-value mass production.
  • the frame member of the present invention is composed of two or more shell members pre-molded with thermoplastic composite materials, which are joined and formed by thermocompression welding, which can stabilize the molding quality of the composite frame member and have light weight. And excellent characteristics such as strong structure.
  • the frame member of the present invention is made of thermoplastic composite material, which is an environmentally friendly material that can be repeatedly heated and molded repeatedly, can be easily repaired, recycled, and reused, and meets modern environmental protection requirements.
  • FIG. 1 is an exploded view of a first preferred embodiment of the present invention to form a shell member by thermocompression of a thermoplastic composite board.
  • FIG. 2 is an exploded schematic view of the two shells and the core mold of the first preferred embodiment (trident member) of the present invention.
  • FIG. 3 is a schematic cross-sectional view of a structure in which two shells and a core mold are assembled before hot-press bonding according to the first preferred embodiment of the present invention.
  • FIG. 4 is a schematic cross-sectional view of the structure of a vehicle frame member after thermocompression bonding according to the first preferred embodiment of the present invention.
  • FIG. 5 is a perspective view of a finished product of a vehicle frame member according to the first preferred embodiment of the present invention.
  • FIG. 6 is a schematic cross-sectional view of a structure in which two shells and a core mold are assembled before hot-press bonding according to a second preferred embodiment of the present invention.
  • FIG. 7 is an exploded schematic view of two shells of a third preferred embodiment (front fork member) of the present invention.
  • FIG. 8 is a finished perspective view of the frame member of the third preferred embodiment of the present invention.
  • Fig. 9 is an exploded schematic view of the component shells of the fourth preferred embodiment (the whole frame) of the present invention.
  • FIG. 10 is a perspective view of a finished product of the fourth preferred embodiment of the present invention.
  • the method for forming a bicycle thermoplastic composite car frame member proposed by the present invention mainly includes the steps of forming a shell member, butting and assembling a shell member, hot press forming a mold, and removing an inner support member. Please refer to FIG. 1 to FIG. 5 to illustrate the first preferred embodiment of the present invention applied to a three-prong member for manufacturing a bicycle frame, in which:
  • Shell forming step As shown in FIGS. 1 and 5, the present invention disassembles a pre-formed frame member 20 into two shell parts 20A and 20B that can be joined together in a left-right halving manner, and forms the shell parts
  • the thermoplastic composite sheet 10 made of thermoplastic carbon fiber material or thermoplastic glass fiber material is selected, and the method is combined with appropriate trimming and trimming methods by means of mold hot press molding, and the thermoplastic composite sheet 10 Hot pressing to form the shell 20A and shell 20B.
  • the thermoplastic composite sheet 10 made of thermoplastic carbon fiber material or thermoplastic glass fiber material is selected, and the method is combined with appropriate trimming and trimming methods by means of mold hot press molding, and the thermoplastic composite sheet 10 Hot pressing to form the shell 20A and shell 20B.
  • each shell 20A and shell 20B includes an outer surface 21 on the outer side, a shell groove 22 surrounded by the shell 20A and shell 20B, and at least two channels for the shell
  • the side end edge of the butting side edge 23 of the shell member 20B will exceed the width of the frame member 20 bisection line by about 2.5 mm to 6 mm, so that when the shell member 20A and the shell member 20B are relatively closed, the corresponding docking
  • the side edge 23 can have an overlapping area with a width of approximately 5 mm to 12 mm.
  • the present invention may split the frame member to be manufactured into three or more shell members that can be relatively joined. The present invention does not specifically limit the number of split shell members.
  • Steps for shell assembly as shown in FIGS. 2 and 3, the shell 20A and shell 20B are butted and combined, and the corresponding butt side edges 23 of the shell 20A and shell 20B are staggered and stacked, In the embodiment shown in the figure, the width of the overlapping area of the corresponding butt edge 23 is approximately 8 mm.
  • the invention provides an inner support 30 inside the shell 20A and the shell 20B when they are butted together
  • the inner supporting member 30 may be various suitable supporting members such as a metal core mold, a foam core mold, a wax core mold, or an air bag. The present invention does not specifically limit it.
  • the inner support 30 is a metal core mold, and in order to be able to remove the inner support 30 smoothly in a subsequent step, the inner support 30 is composed of a middle mold 31, an upper mold 32 and a lower mold 33 And, the inner support member 30 is provided with a concession concave edge 34 opposite to each other in the overlapping area corresponding to the abutting side edges 23.
  • Mold hot press forming step As shown in FIGS. 3 and 4, the hot press forming of the mold, with the support or pressurization of the inner support 30, butts the shell 20A and the shell 20B relative to each other
  • the overlapping areas of the side edges 23 are thermocompression welded to form a welded region 24 that is integrated, and the shell 20A and the shell 20B are joined and formed into the frame member 20 described above; wherein, the butt joint in this embodiment
  • the overlapping regions of the side edges 23 will match the corresponding yielding concave edges 34 to form a thickened welding protrusion 241 to further strengthen the structural strength of the welding region 24 of the vehicle frame member 20.
  • Step of removing the inner support member As shown in FIGS. 4 and 5, after completing the mold hot press forming step, the inner support member 30 located inside the frame member 20 is removed.
  • the removal step is first Withdraw the middle module 31, and then withdraw the upper module 32 and the lower module 33 in sequence, successfully complete the steps of removing the inner support member 30, together with appropriate trimming and trimming methods, you can complete the production.
  • 5 shows the finished product of the frame member 20 shown in FIG.
  • thermoplastic composite sheet is first hot-pressed with a mold to form a pair of opposing shell parts 20A and 20B, and then the pair of shell parts are hot-pressed by a mold 20A, the shell 20B is joined by thermocompression welding to form a complete composite car frame member 20.
  • the entire production molding time is fast, usually only about 5 minutes of molding time, compared to the existing thermoset carbon fiber car frame member.
  • the invention improves the molding speed by more than 10 times, and can save labor costs. It is very suitable for mass production and has deep industrial utilization value.
  • the finished product of the frame member 20 includes two shell members 20A and 20B that are formed by thermocompression molding and are relatively connected together.
  • the shell member 20A and the shell member 20B Each of the joined parts forms a fusion zone 24 that is welded together.
  • the thermoplastic composite material is first hot-pressed into the shell 20A and the shell 20B, and then the thermocompression welding is performed to form the composite, which can stabilize the molding quality of the composite vehicle frame member 20 and have the characteristics of light weight and strong structure
  • the thermoplastic composite material can be used to repeatedly heat the molding characteristics, which can be easily repaired, recycled and reused, in line with current environmental protection requirements.
  • the shell 40A and the shell 40B each have an outer surface 41, a shell groove 42 and at least two butt side edges 43, each phase
  • the corresponding mating side edges 43 are provided with matching stepped engagement surfaces, so that the mating side edges 43 of the shell 40A and the shell 40B are matched and overlapped with the stepped engagement surfaces, and the inner support 30A is not provided with a place In the form of a concave edge, the opposing butt side edges 43 of the shell 40A and the shell 40B are joined together by thermocompression welding.
  • FIG. 7 and FIG. 8 is an embodiment of the present invention applied to the manufacture of bicycle front forks.
  • the shell 50A and the shell 50B are respectively provided with at least two butt side edges 51 for the shell 50A and the shell 50B to engage and connect the shell 50A and the shell 50B, so that the shell 50A ,
  • the butt side edges 51 of the shell member 50B are joined together by thermocompression welding to form an integral fusion zone 52, which is combined with the fork head member 53 and fork head member 54 to form a joint as shown in FIG. 8 for use as a bicycle front.
  • Fork truck frame member 50 fork truck frame member 50.
  • FIG. 9 and FIG. 10 is an embodiment of the present invention applied to the manufacture of the entire bicycle.
  • This embodiment includes a frame member 60 as a front triangle of the frame and a rear fork
  • the frame member 70 and the frame member 80 as the chainstay; the frame member 60 is divided into two shell parts 60A and 60B that can be joined together in a left and right way.
  • the frame The component 70 is disassembled into two shell parts 70A and 70B that can be joined together in the above-mentioned manner.
  • the frame member 80 is also disassembled into two shell parts 80A and 80B that can be joined together in the above-mentioned manner.
  • the shell member 60A, 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 channels for making each of the two correspond to the shell member 60A, the shell member 60B, the shell member 70A, the shell member 70B, the shell member 80A, the shell member 80B, the butt side edge 61, the butt side edge 71, and the butt side edge 81 that are joined together, so that the two corresponding shell parts 60A, 60B, 70A, 70B,
  • the abutting side edges 61, abutting side edges 71, and abutting side edges 81 of the shell member 80A and the shell member 80B are joined together by thermocompression welding, wherein the butted side edges 61 are joined together by thermocompression welding 62.
  • a bicycle frame including each frame member 60, frame member 70, and frame member 80 as shown in FIG. 10 is formed .

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  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Composite Materials (AREA)
  • Lining Or Joining Of Plastics Or The Like (AREA)

Abstract

一种自行车热塑复合材车架构件（20）的成型方法及其成品，先将热塑复合板材（10）以热压成型出两个或多个能够相对合的壳件（20A、20B）；接着将两个或多个壳件（20A、20B）对接组合，并于两个或多个壳件（20A、20B）的内部设有内支撑件（30）；接着直接将两个或多个壳件（20A、20B）的对接侧缘（23）交错叠合，再将交叠区域以热压熔接方式连结成一体，让两个或多个壳件（20A、20B）接合成型为完整的车架构件（20）；接着拆除内支撑件（30），搭配裁边修整手段，即可制成热塑复合材车架构件（20）。该成型方法成型时间短且节省人力，适合大量生产制造，成型品质稳定，成品重量轻、结构强固。

Description

自行车热塑复合材车架构件的成型方法及其成品 技术领域
本发明涉及一种自行车的车架构件的成型技术，尤指一种采用热塑复合材料以热压接合方式成型的自行车热塑复合材车架构件成型方法及其成品。
背景技术
现有以碳纤维复合材料制成的自行车的车架构件，通常是采用如公开号为CN1143010A、CN101786329A及CN102729484A等的中国专利文献所公开的车架构件制造方法，主要是利用发泡材料或气袋制作成芯模，接着以热固形碳纤维的预浸材料于芯模上积层形成预成型体，接着将积层完成的预成型体置入成型模具中加热加压而固化成型，接着打开成型模具及将位于碳纤维壳层内部的芯模取出而完成脱模，最后再进行细部的修饰加工，即可制作出碳纤维车架构件的成品。
现有的碳纤维车架构件成型方法，虽然可以利用成型模具一次成型，不过受限于热固形碳纤维与树脂的成型温度和压力等条件，其成型时间大约需要50分钟到60分钟，成型时间相当长且成本高，不适合大量生产。如果现有的成型方法要达到量产化的需求，必须准备多套成型模具及操作人员同时作业，导致模具成本及人工成本的耗费。
现有以热固形碳纤维制成的车架构件，容易因为芯模的加压支撑强度不足或不平均，导致成型的车架构件的表面品质及结构强度不稳定，并且在车架构件成型之后，车架构件的外型就不能再加热改变，无法进行修理和回收再利用，造成现有复合材料车架构件的实施应用受到相当多的限制。
发明内容
为解决现有自行车的热固形碳纤维车架构件的成型方法存在不适合大量生产及成型品质不稳定的问题，本发明提出一种自行车热塑复合材车架构件的成型方法，本发明先将热塑复合板材以模具热压形成两个或多个可相对合的壳件，再以模具热压方式将各壳件对合热压熔接连结成完整的车架构件，快速地将热塑复合材车架构件制作成型，非常适合大量生产制造，有效解决现有技术所存在的问题。
为解决现有自行车的热固形碳纤维车架构件的品质不稳定及难以进行修理和回收 再利用的问题，本发明提出一种自行车热塑复合材车架构件，本发明是以两个或多个预先成型的热塑复合材壳件对合热压熔接连结成型，能够让车架构件的结构强固且成型品质稳定，并且可以进行修理和回收处理，有效解决现有技术所存在的问题。
本发明解决技术问题提出一种自行车热塑复合材车架构件的成型方法，包括：
壳件成型步骤：将热塑复合板材以模具热压形成两个以上能够相对合的壳件，各壳件包含有一外表面、一由所述壳件包围形成的壳槽及至少两道用以让各壳件相对接合连结的对接侧缘；
壳件对接组合步骤：将各壳件对接组合，让各壳件相对应的对接侧缘交错叠合，并于以各壳件包围形成的内部设置一能对各壳件形成支撑的内支撑件；
模具热压成型步骤：以模具热压成型方式，将各壳件相对接合的对接侧缘的交叠区域，以热压熔接方式形成连结成一体的熔接区，让各壳件接合形成一车架构件；
拆除内支撑件步骤：将位于该车架构件内部的该内支撑件拆除，搭配裁边修整手段，制成该车架构件的成品。
较佳的，所述壳件成型步骤中，所述热塑复合板材为热塑形碳纤维板材或热塑形玻璃纤维板材。
较佳的，所述模具热压成型步骤中，所述车架构件包括两个能够相对合的所述壳件。
较佳的，所述模具热压成型步骤中，所述熔接区形成一呈增厚形态的熔接凸体。
较佳的，其中所述内支撑件于对应所述对接侧缘的交叠区域的位置设有一让位凹缘，所述熔接区形成匹配该让位凹缘的所述熔接凸体。
较佳的，所述内支撑件为金属芯模且包括中模件、一上模件和一下模件。
较佳的，其中所述壳件对接组合步骤中，相对合的所述对接侧缘以相匹配叠合的阶梯状衔接面形成交错叠合。
本发明解决技术问题提出一种自行车热塑复合材车架构件，该自行车热塑复合材车架构件包括两个以上以热塑复合材料热压成型且能够相对合的壳件，各壳件包含有一位于外侧的外表面、一由所述壳件包围形成的壳槽，以及至少两道用以让各壳件相对接合连结的对接侧缘，各壳件相对应的对接侧缘相互交错叠合且熔接形成一体连结的熔接区。
较佳的，其中所述的熔接区具有一厚度大于所述壳件的厚度而呈增厚形态的熔接凸体。
相较于现有技术，本发明提出的技术手段可获得的功效增进包括：
1.本发明先将热塑复合板材以模具热压形成两个或多个可相对合的壳件，再将两个或多个壳件对合热压熔接连结成完整的车架构件，本发明制造成型快速，通常大约只需要5分钟的成型时间，并且能够节省人工成本，非常适合大量生产制造，具备高价值的量产性。
2.本发明的车架构件是由两个或多个以热塑复合材料预先成型的壳件，对合热压熔接连结成型，能够让复合材车架构件的成型品质稳定，并且具备重量轻和结构强固等优异特性。
3.本发明的车架构件是以热塑复合材料制成，热塑复合材料为可多次重复加热塑型的环保材料，能够方便地进行修理和回收再利用，符合现代化的环保要求。
附图说明
图1是本发明第一较佳实施例以热塑复合板材热压形成壳件的分解图。
图2是本发明第一较佳实施例(三叉构件)的两个壳件及芯模的分解示意图。
图3是本发明第一较佳实施例在热压接合前将两个壳件及芯模对合组配的结构断面示意图。
图4是本发明第一较佳实施例在热压接合后的车架构件的结构断面示意图。
图5是本发明第一较佳实施例的车架构件的成品立体图。
图6是本发明第二较佳实施例在热压接合前将两个壳件及芯模对合组配的结构断面示意图。
图7是本发明第三较佳实施例(前叉构件)的两个壳件的分解示意图。
图8是本发明第三较佳实施例的车架构件的成品立体图。
图9是本发明第四较佳实施例(整部车架)的组成壳件的分解示意图。
图10是本发明第四较佳实施例的成品立体图。
具体实施方式
本发明提出的自行车热塑复合材车架构件的成型方法，主要包括：壳件成型步骤、壳件对接组合步骤、模具热压成型步骤及拆除内支撑件步骤等步骤。请参阅图1至图5所示，以本发明应用于制作自行车车架的三叉构件的第一较佳实施例来进行说明，其中：
壳件成型步骤：如图1及图5所示，本发明将预备成型的一车架构件20以左右对分方式拆成两个能够相对合的壳件20A、壳件20B，在壳件成型步骤中，选用以热塑形 碳纤维材料或热塑形玻璃纤维材料制成的热塑复合板材10，以模具热压成型的方式，搭配适当的裁边修整手段，将所述的热塑复合板材10热压形成所述的壳件20A、壳件20B。如图2所示，各壳件20A、壳件20B包含有一位于外侧的外表面21、一由所述壳件20A、壳件20B包围形成的壳槽22，以及至少两道用以让该壳件20A、壳件20B对合连结的对接侧缘23，在如图所示的实施例中，为了让该壳件20A、壳件20B的对接侧缘23能够相互交错叠合，壳件20A、壳件20B的对接侧缘23的侧端缘会超出该车架构件20对分线大约2.5mm至6mm左右的宽度，让该壳件20A、壳件20B相对合时，相对应的所述对接侧缘23能够具有宽度大约5mm至12mm的交叠区域。在其他的实施例中，本发明可以将预备制造成型的车架构件拆分成三个或多个能够相对接合的壳件，本发明对于拆分的壳件数量不作特定的限制。
壳件对接组合步骤：如图2及图3所示，将该壳件20A、壳件20B对接组合，并且让该壳件20A、壳件20B各相对应的对接侧缘23交错叠合，在如图所示的实施例中，相对应的所述对接侧缘23的交叠区域的宽度大约为8mm。并且为在后续的模具热压成型步骤时，该壳件20A、壳件20B的内部能够获得足够的支撑，本发明在该壳件20A、壳件20B对接组合时的内部设有一内支撑件30，该内支撑件30可以为金属芯模、发泡材芯模、蜡制芯模或气袋等各种适当的支撑构件，本发明不作特定的限制，在如图所示的实施例中，该内支撑件30为金属芯模，并且为在后续步骤能够将该内支撑件30顺利拆除，该内支撑件30是由一中模件31、一上模件32和一下模件33所组成，并且该内支撑件30于对应各所述对接侧缘23的交叠区域各相对设有一让位凹缘34。
模具热压成型步骤：如图3及图4所示，以模具热压成型的方式，搭配该内支撑件30的支撑或加压作用，将该壳件20A、壳件20B相对合的各对接侧缘23的交叠区域热压熔接形成连结成一体的熔接区24，让该壳件20A、壳件20B接合成型为所述的车架构件20；其中，在本实施例中的所述对接侧缘23的交叠区域会匹配相对应的让位凹缘34而形成一呈增厚形态的熔接凸体241，进一步强化该车架构件20的熔接区24的结构强度。
拆除内支撑件步骤：如图4及图5所示，在完成模具热压成型步骤后，将位于该车架构件20内部的该内支撑件30拆除，在本实施例中，拆除步骤是先将该中模件31抽出，再依序将该上模件32及该下模件33抽出，顺利完成拆除该内支撑件30的步骤，搭配适当的裁边修整手段，即可制作完成如图5所示的车架构件20的成品。
本发明的热塑复合材车架构件的成型方法，先将热塑复合板材以模具热压形成一对 可相对合的壳件20A、壳件20B，再以模具热压方式将该对壳件20A、壳件20B对合热压熔接连结成完整的复合材车架构件20，整个制作成型的时间快速，通常大约只需要5分钟的成型时间，相较于现有热固形碳纤维车架构件大约50分钟至60分钟的成型时间，本发明提升了大约10倍以上的成型速度，并且能够节省人工成本，非常适合大量生产制造，深具产业利用价值。
如图2及图5所示，该车架构件20的成品包括两个以热塑复合材料热压成型且相对合连结的壳件20A、壳件20B，于该壳件20A、壳件20B的各个对合连结的部位形成熔接成一体的熔接区24。本发明先将热塑复合材热压成壳件20A、壳件20B后再对合热压熔接连结成型，能够让复合材车架构件20的成型品质稳定，并且具备重量轻和结构强固的特性，同时可以利用热塑复合材料可以多次重复加热塑型的特性，能够方便地进行修理和回收再利用，符合当前的环保要求。
请参阅图6所示的第二较佳实施例，在本实施例中的该壳件40A、壳件40B均具有一外表面41、一壳槽42及至少两道对接侧缘43，各相对应的对接侧缘43设有相匹配的阶梯状衔接面，让该壳件40A、壳件40B的各对接侧缘43以阶梯状衔接面匹配叠合，搭配该内支撑件30A未设置让位凹缘的方式，让该壳件40A、壳件40B的各相对合的对接侧缘43热压熔接连结成一体。
请参阅图7及图8所示的第三较佳实施例，其为本发明应用于制作自行车前叉的实施例，本实施例的车架构件50是以前后方式拆成两个能够相对合的壳件50A、壳件50B，并于该壳件50A、壳件50B各设有至少两道用以让该壳件50A、壳件50B对合连结的对接侧缘51，让该壳件50A、壳件50B的各对接侧缘51对合热压熔接连结成一体的熔接区52，搭配叉头件53、叉头件54的组接连结，成型出如图8所示用以作为自行车前叉的车架构件50。
请参阅图9及图10所示的第四较佳实施例，其为本发明应用于制作整部自行车的实施例，本实施例包括作为车架前三角的车架构件60、作为后上叉的车架构件70及作为后下叉的车架构件80等部分；其中的该车架构件60是以左右对分方式拆成两个能够相对合的壳件60A、壳件60B，该车架构件70是以上下方式拆成两个能够相对合的壳件70A、壳件70B，该车架构件80也是以上下方式拆成两个能够相对合的壳件80A、壳件80B，并于各壳件60A、壳件60B、壳件70A、壳件70B、壳件80A、壳件80B各设有至少两道用以让各两相对应壳件60A、壳件60B、壳件70A、壳件70B、壳件80A、壳件80B对合连结的对接侧缘61、对接侧缘71、对接侧缘81，让各两相对应的壳件60A、壳件 60B、壳件70A、壳件70B、壳件80A、壳件80B的各对接侧缘61、对接侧缘71、对接侧缘81对合热压熔接连结成一体，其中所述的对接侧缘61对合热压熔接成一体的熔接区62，搭配各车架构件60、车架构件70、车架构件80的组接连结，成型出如图10所示包括各车架构件60、车架构件70、车架构件80的自行车车架。
以上的详细说明，提供本发明所属技术领域中的普通技术人员了解本发明的技术内容，并非对本发明作特定形式的限制，利用本发明揭示的技术特征所作出局部更动或修饰的等效实施例，均仍属于本发明的保护范围。

Claims (10)

  1. 一种自行车热塑复合材车架构件的成型方法，其特征在于，所述自行车热塑复合材车架构件的成型方法包括：
    壳件成型步骤：将热塑复合板材以模具热压形成两个以上能够相对合的壳件，各所述壳件包含有一外表面、一由所述壳件包围形成的壳槽及至少两道用以让各所述壳件相对接合连结的对接侧缘；
    壳件对接组合步骤：将各所述壳件对接组合，让各所述壳件相对应的所述对接侧缘交错叠合，并于以各所述壳件包围形成的内部设置一能对各所述壳件形成支撑的内支撑件；
    模具热压成型步骤：以模具热压成型方式，将各所述壳件相对接合的所述对接侧缘的交叠区域，以热压熔接方式形成连结成一体的熔接区，让各所述壳件接合形成一车架构件；
    拆除内支撑件步骤：将位于所述车架构件的内部的所述内支撑件拆除，搭配裁边修整手段，制成所述车架构件的成品。
  2. 根据权利要求1所述的自行车热塑复合材车架构件的成型方法，其特征在于，所述壳件成型步骤中，所述热塑复合板材为热塑形碳纤维板材或热塑形玻璃纤维板材。
  3. 根据权利要求2所述的自行车热塑复合材车架构件的成型方法，其特征在于，所述车架构件包括两个能够相对合的所述壳件。
  4. 根据权利要求1、2或3所述的自行车热塑复合材车架构件的成型方法，其特征在于，所述模具热压成型步骤中，所述熔接区形成一呈增厚形态的熔接凸体。
  5. 根据权利要求4所述的自行车热塑复合材车架构件的成型方法，其特征在于，所述内支撑件于对应所述对接侧缘的交叠区域的位置设有一让位凹缘，所述熔接区形成匹配所述让位凹缘的所述熔接凸体。
  6. 根据权利要求5所述的自行车热塑复合材车架构件的成型方法，其特征在于，所述内支撑件为金属芯模且包括中模件、一上模件和一下模件。
  7. 根据权利要求1、2或3所述的自行车热塑复合材车架构件的成型方法，其特征在于，所述壳件对接组合步骤中，相对合的所述对接侧缘以相匹配叠合的阶梯状衔接面形成交错叠合。
  8. 一种自行车热塑复合材车架构件，其特征在于，所述自行车热塑复合材车架构 件包括两个以上以热塑复合材料热压成型且能够相对合的壳件，各所述壳件包含有一位于外侧的外表面、一由所述壳件包围形成的壳槽，以及至少两道用以让各所述壳件相对接合连结的对接侧缘，各所述壳件相对应的所述对接侧缘相互交错叠合且熔接形成一体连结的熔接区。
  9. 根据权利要求8所述的自行车热塑复合材车架构件，其特征在于，所述熔接区具有一厚度大于所述壳件的厚度而呈增厚形态的熔接凸体。
  10. 根据权利要求8或9所述的自行车热塑复合材车架构件，其特征在于，所述热塑复合材为热塑形碳纤维材料或热塑形玻璃纤维材料。
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