阅读说明：本技术 一种一体碳纤维前叉及预制成型工艺 (Integrated carbon fiber front fork and prefabricating and forming process ) 是由 杨军云 韩彬彬 范毅 于 2021-08-31 设计创作，主要内容包括：本发明适用于自行车制造的技术领域,公开了一种一体碳纤维前叉及预制成型工艺。本发明提供的一种一体碳纤维前叉,包括叉肩和连接在叉肩一侧的竖管,叉肩和竖管一体成型。叉肩内设置有PU壳A和PU壳B,在PU壳A和PU壳B之间设有隔板；叉肩和竖管均为碳纤维结构。并通过在PU壳A和PU壳B的表面铺设碳纤维片的方式使成型的碳纤维内设有隔板。使自行车可以承受更大的正面撞击力。(The invention is applicable to the technical field of bicycle manufacturing, and discloses an integrated carbon fiber front fork and a prefabricating and forming process. The invention provides an integrated carbon fiber front fork which comprises a fork shoulder and a vertical pipe connected to one side of the fork shoulder, wherein the fork shoulder and the vertical pipe are integrally formed. A PU shell A and a PU shell B are arranged in the fork shoulder, and a partition plate is arranged between the PU shell A and the PU shell B; the fork shoulder and the vertical pipe are both of carbon fiber structures. And a clapboard is arranged in the formed carbon fiber in a mode of paving carbon fiber sheets on the surfaces of the PU shell A and the PU shell B. The bicycle can bear larger frontal impact force.)

1. An integrated carbon fiber front fork comprises a fork shoulder (1) and a vertical pipe (2) connected to one side of the fork shoulder (1), wherein the fork shoulder (1) and the vertical pipe (2) are integrally formed; the method is characterized in that: a PU shell A (3) and a PU shell B (4) are arranged in the fork shoulder (1), and a carbon fiber reinforced clapboard (11) is arranged between the PU shell A (3) and the PU shell B (4); the fork shoulder (1) and the vertical pipe (2) are both of carbon fiber structures.

2. The integrated carbon fiber front fork of claim 1, wherein: a fork hook is integrally formed on one side of the fork shoulder (1) far away from the vertical pipe (2).

3. The integrated carbon fiber front fork prefabricating and forming process is characterized in that: a molding process for making the integrated carbon fiber front fork of any one of claims 1-3.

4. The integrated carbon fiber front fork prefabrication and molding process of claim 3, comprising the following steps:

a) selecting a PU shell A (3) and a PU shell B (4) which are matched with the fork shoulder (1) in structure;

b) laying layers with carbon fibers along the shape of the PU shell A (3), and laying a plurality of layers;

c) laying layers with carbon fibers along the shape of the PU shell B (4), and laying a plurality of layers;

d) overlapping the PU shell A (3) and the PU shell B (4) after being paved, so that the PU shell A (3) and the PU shell B (4) are combined with the carbon fiber coated outside into a whole;

e) the joints of the PU shell A (3) and the PU shell B (4) which are layered and the fork hook are all provided with gradual layers, and the joints of the PU shell A (3) and the PU shell B (4) which are layered and the vertical pipe (2) are all provided with gradual layers;

f) pre-embedding air bags in the PU shell A (3), the PU shell B (4) and the vertical pipe (2) after the layers are laid;

g) coating the PU shell A (3), the PU shell B (4), the vertical pipe (2) and the fork hook which are layered into a whole through carbon fibers to obtain a prefabricated product of the carbon fiber front fork;

h) after connecting an air nozzle on the air bag, putting the prefabricated product into a mould;

i) placing the mold with the product on a forming furnace platform, and heating and curing the air bag after air is introduced into the air bag to obtain a carbon fiber front fork;

j) and polishing and baking finish are carried out on the carbon fiber front fork to obtain a finished product.

5. The integrated carbon fiber front fork prefabrication and molding process of claim 4, wherein: the number of the paving layers in the step b) and the step c) is 1-5.

6. The integrated carbon fiber front fork prefabrication and molding process of claim 4, wherein: the heating temperature in the step i) is 130-180 ℃; the heating time is 25-40 minutes.

Technical Field

The invention relates to the technical field of bicycle manufacturing, in particular to an integrated carbon fiber front fork and a prefabricating and forming process.

Background

The variety of bicycle is various, including road bicycle, mountain bike, electric bicycle and electric tricycle etc. along with the continuous improvement of people's environmental protection consciousness and the continuous development and the maturity of electric motor car technique, electric bicycle, electric tricycle have become the main vehicle of people's trip, and functional stronger bicycles such as mountain bike and road bike also more and more receive liking of people. Wherein, in the bicycle, the manufacturing process of the front fork can not be separated.

Currently, the front fork is manufactured by adopting an air bag forming process, as shown in fig. 1, the air bag forming process has the greatest defect that carbon fibers cannot be straightened and extended because the air bag routing is disordered, so that the strength of the carbon fiber front fork is weakened. The impact resistance can only be satisfied by increasing the thickness of the carbon fiber in order to satisfy the strength.

Another kind of manufacturing process of front fork is whole shell that built-in PU shell adopted as an organic whole, as shown in fig. 2, makes the more smooth-going that the carbon fiber can extend, nevertheless because the bicycle receives the striking when going, can make front fork shoulder platform unilateral atress, causes the carbon fiber unilateral fracture easily to influence product strength, also can only solve through increasing product thickness at present.

The invention patent with publication number CN102529111A discloses a manufacturing method of an integrated bicycle front fork, which is characterized in that: the method comprises the following steps of (1) integrally layering and filling carbon fiber prepreg by using a split combined type integral external mold consisting of a front fork upper mold A, a front fork lower mold C and a hook fork insert mold B which can form the appearance of a carbon fiber composite bicycle front fork and a latex liner auxiliary mold D matched with the external mold; and the carbon fiber material filled in the die forms an integrated seamless bicycle front fork component by inflating through a pressure air source. The front fork structure of this patent can't deal with the impact that receives when the bicycle traveles, leads to the easy unilateral fracture of front fork.

The invention discloses a molding method of a reinforced carbon fiber bicycle component, which is suitable for manufacturing a bicycle component and comprises the following steps of manufacturing a hollow thin-walled mandrel by using a foaming material, wherein the mandrel is provided with at least one molding groove formed on the surface. A releasing layer is arranged on the surface of the mandrel, and a carbon fiber material is wound on the surface of the releasing layer. Inflating the air bag, and heating and pressurizing the carbon fiber material and the mandrel to harden and form the carbon fiber material. And taking out the air bag and the mandrel, and forming the carbon fiber material into the bicycle component after hardening. The bicycle component is hollow and is provided with at least one reinforcing rib which is formed on the inner circumferential surface of the bicycle component and corresponds to the forming groove. The bicycle front fork is manufactured in a single shell mode, although the process has similar parts, when the partition plate cannot be manufactured in the middle of the single shell, the strength is low.

Disclosure of Invention

The invention aims to overcome the defects of the prior art and provides an integrated carbon fiber front fork, wherein a PU shell A and a PU shell B are arranged in a fork shoulder to enable a carbon fiber reinforced clapboard to be arranged in the front fork during the forming process, and the integrated carbon fiber front fork aims to solve the technical problem that a bicycle is easy to break when subjected to a front device in the prior art.

In order to achieve the purpose, the invention provides an integrated carbon fiber front fork, which comprises a fork shoulder and a vertical pipe connected to one side of the fork shoulder, wherein the fork shoulder and the vertical pipe are integrally formed; a PU shell A and a PU shell B are arranged in the fork shoulder, and a carbon fiber reinforced clapboard is arranged between the PU shell A and the PU shell B; the fork shoulder and the vertical pipe are both of carbon fiber structures.

Preferably, a fork hook is integrally formed on one side of the fork shoulder, which is far away from the vertical pipe.

In order to manufacture the integrated carbon fiber front fork, the invention provides an integrated carbon fiber front fork prefabricating and forming process, and aims to manufacture a forming process which improves the strength of a bicycle front fork and is optimized through the improvement of the process.

In order to achieve the purpose, the invention provides an integrated carbon fiber front fork, which is a prefabricating and forming process, and comprises the following steps:

a) selecting a PU shell A and a PU shell B which are matched with the fork shoulder structure;

b) laying layers with carbon fibers along the shape of the PU shell A, and finishing after laying a plurality of layers;

c) laying layers with carbon fibers along the shape of the PU shell B, and finishing after laying a plurality of layers;

d) overlapping the PU shell A (3) and the PU shell B (4) after being paved, so that the PU shell A (3) and the PU shell B (4) are combined with the carbon fiber coated outside into a whole;

e) the joints of the PU shells A and B and the fork hooks after being layered are provided with gradual layers, and the joints of the PU shells A and B and the vertical pipes after being layered are provided with gradual layers;

f) pre-embedding air bags in the PU shell A, the PU shell B and the vertical pipe after the layers are laid;

g) coating the PU shell A and the PU shell B, the vertical pipe and the fork hook which are layered into a whole through carbon fibers to obtain a prefabricated product of the carbon fiber front fork;

h) after connecting an air nozzle on the air bag, putting the prefabricated product into a mould;

i) placing the mold with the product on a forming furnace platform, and heating and curing the air bag after air is introduced into the air bag to obtain a carbon fiber front fork;

j) and polishing and baking finish are carried out on the carbon fiber front fork to obtain a finished product.

Compared with the prior art, the integrated carbon fiber front fork and the prefabricating and forming process have the beneficial effects that:

1. be provided with the carbon fiber in the fork shoulder and strengthen the baffle, improved the holistic intensity of front fork, can bear higher front impact force, be difficult to the fracture, the carbon fiber is strengthened the baffle and has been formed when spreading layer PU shell A and PU shell B, and the integration degree is high.

2. The PU shell A and the PU shell B are arranged in the fork shoulders and have a certain buffering effect.

3. The carbon fiber sheets are laid on the PU shell A and the PU shell B, so that the carbon fiber sheets have a certain shape and the laying process is simple.

The features and advantages of the present invention will be described in detail by embodiments in conjunction with the accompanying drawings.

Drawings

FIG. 1 is a schematic view of the structure of the present invention using an air bag forming process.

FIG. 2 is a schematic structural diagram of the present invention using a built-in PU shell molding process.

Fig. 3 is a schematic structural diagram of a forming process of an integrated carbon fiber front fork according to an embodiment of the present invention.

In the figure: 1. a fork shoulder; 11. a carbon fiber reinforced separator; 2. a vertical tube; 3. a PU shell A; 4. PU shell B.

Detailed Description

In order to make the objects, technical solutions and advantages of the present invention more apparent, the present invention is further described in detail below with reference to the accompanying drawings and examples. It should be understood, however, that the description herein of specific embodiments is only intended to illustrate the invention and not to limit the scope of the invention. Moreover, in the following description, descriptions of well-known structures and techniques are omitted so as to not unnecessarily obscure the concepts of the present invention.

In the description of the present invention, it should be noted that when an element is referred to as being "fixed" or "disposed" to another element, it can be directly on the other element or be indirectly on the other element. When an element is referred to as being "connected to" another element, it can be directly connected to the other element or be indirectly connected to the other element.

In the description of the present invention, it should be noted that the terms "center", "length", "width", "thickness", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", etc. indicate orientations or positional relationships based on the orientations or positional relationships shown in the drawings or the orientations or positional relationships in which the products of the present invention are conventionally placed when used, and are merely used for convenience of describing and simplifying the description, but do not indicate or imply that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and thus, should not be construed as limiting the present invention. Furthermore, the terms "first," "second," "third," and the like are used solely to distinguish one from another and are not to be construed as indicating or implying relative importance. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of the present invention, "a plurality" means two or more unless specifically defined otherwise. The meaning of "a number" is one or more unless specifically limited otherwise.

In the description of the present invention, it should also be noted that, unless otherwise explicitly specified or limited, the terms "disposed," "mounted," "connected," and "connected" are to be construed broadly and may, for example, be fixedly connected, detachably connected, or integrally connected; can be mechanically or electrically connected; they may be connected directly or indirectly through intervening media, or they may be interconnected between two elements. The specific meanings of the above terms in the present invention can be understood in specific cases to those skilled in the art.

Referring to fig. 3, an integrated carbon fiber front fork according to an embodiment of the present invention includes a fork shoulder 1 and a vertical tube 2 connected to one side of the fork shoulder 1, where the fork shoulder 1 and the vertical tube 2 are integrally formed. A PU shell A3 and a PU shell B4 are arranged in the fork shoulder 1, and a carbon fiber reinforced clapboard 11 is arranged between the PU shell A3 and the PU shell B4; fork shoulder 1 and standpipe 2 are carbon fiber structure. The carbon fiber reinforced clapboard 11 has the function of reinforcing the strength of the whole carbon fiber, so that the bicycle can bear larger frontal impact force.

In an alternative embodiment, a fork hook is integrally formed on the side of the fork shoulder 1 remote from the standpipe 2. The shell structure of the carbon fiber front fork can adopt a front fork structure disclosed in the publication No. CN 203864887U.

The manufacturing method of the integrated carbon fiber front fork comprises the following steps:

a) and selecting a PU shell A3 and a PU shell B4 which are matched with the structure of the fork shoulder 1. The fork shoulder shapes manufactured by selecting different PU shells A and PU shells B are also different, and can be selected according to the conditions.

b) And laying carbon fibers along the shape of the PU shell A3, and laying a plurality of layers to finish the process. The angle of the material is designed and cut according to the shape and strength requirements of the product, the material is cut into a plurality of pieces according to the shape of the product, and the carbon fiber pieces are laid, so that the overall precision is better.

c) And laying carbon fibers along the shape of the PU shell B4, and laying a plurality of layers to finish the process.

d) And overlapping the PU shell A (3) and the PU shell B (4) after being paved, so that the PU shell A (3) and the PU shell B (4) are combined with the carbon fiber coated outside into a whole. The structures of the PU shell a and the PU shell B are shown in fig. 3. With PU shell A and PU shell B curved part near, because of there is the carbon fiber in the surface when spreading PU shell A and PU shell B, have carbon fiber to strengthen the baffle between PU shell A and the PU shell B when combining together, the integration degree is high.

e) The connection parts of the layered PU shell A3 and the layered PU shell B4 with the fork hooks are all provided with gradual layers, and the connection parts of the layered PU shell A3 and the layered PU shell B4 with the vertical pipe 2 are all provided with gradual layers. PU shell A3 and PU shell B4's upper and lower both sides all have gradually the layer, and the upper end is used for connecting standpipe 2, and the lower extreme is used for connecting the fork hook, reserves gradually the layer after, the later stage can be better couple together each part.

f) And pre-embedding air bags in the PU shell A3, the PU shell B4 and the vertical pipe 2 after the layers are paved.

g) Coating the PU shell A3 and the PU shell B4, the vertical tube 2 and the fork hook which are laminated into a whole through carbon fibers to obtain a prefabricated product of the carbon fiber front fork;

h) and connecting an air nozzle on the air bag, and then putting the prefabricated product into a mold. The mold may be a common mold for manufacturing a front fork disclosed in patent publication No. CN203864887U or CN 101786329A.

i) And placing the mold with the product on a forming furnace platform, and heating and curing the air bag after air is introduced into the air bag to obtain the carbon fiber front fork. After the air bag is filled with air, the carbon fiber keeps an expansion state and cannot shrink in the heating process.

j) And polishing and baking finish are carried out on the carbon fiber front fork to obtain a finished product.

In an alternative embodiment, the number of layers in step b and step c is 1-5. Two layers are generally chosen in actual manufacturing.

In an alternative embodiment, the heating temperature in step i is 130-; the heating time is 25-40 minutes. The best front fork can be obtained by selecting the heating temperature of 150 ℃ and the heating time of 35 minutes in practical manufacture.

The above description is only for the purpose of illustrating the preferred embodiments of the present invention and is not to be construed as limiting the invention, and any modifications, equivalents or improvements made within the spirit and principle of the present invention should be included in the scope of the present invention.