Method for making a carbon fiber wheel rim

Abstract

A method for making a carbon fiber wheel rim includes: preparing an outer supporting piece; winding a carbon-fiber yarn around the outer supporting piece to form carbon fiber layers and to constitute an engaging seat preform; connecting an inner supporting piece to the engaging seat preform; connecting a reinforcement piece to the inner supporting piece; winding a carbon-fiber yarn around an assembly of the engaging seat preform, the inner supporting piece and the reinforcement piece to form carbon fiber layers; fixing the assembly with the carbon fiber layers to form an outer frame preform; and cutting the outer frame preform and the engaging seat preform to form a trench and removing the outer supporting piece therefrom.

Claims

1. A method for making a carbon fiber wheel rim, the carbon fiber wheel rim having a circular engaging seat formed with a circular engaging groove for engagement with a tire, the method comprising: preparing a circular outer supporting piece having a cross-section that is complementary in shape with the circular engaging groove; winding continuously and circumferentially at least one first carbon-fiber yarn around the circular outer supporting piece to form a plurality of first carbon fiber layers, each being formed by winding the first carbon-fiber yarn in a mutually-different winding angle, the circular outer supporting piece and the first carbon fiber layers constituting a circular engaging seat preform; connecting a circular inner supporting piece to the circular engaging seat preform; connecting a circular reinforcement piece to the circular inner supporting piece oppositely of the circular engaging seat preform so that the circular engaging seat preform, the circular inner supporting piece and the circular reinforcement piece constitute an assembly; winding continuously and circumferentially at least one second carbon-fiber yarn around the assembly to form a plurality of second carbon fiber layers, each being formed by winding the second carbon-fiber yarn in a mutually-different winding angle; fixing the assembly with the second carbon fiber layers to form an outer frame preform on the assembly, the outer frame preform having an outer circular surface distal from the circular reinforcement piece; and removing part of the outer frame preform and part of the circular engaging seat preform to form a circular trench, followed by removing the circular outer supporting piece from the circular trench to form the circular engaging groove of the circular engaging seat and an outer frame.

2. The method of claim 1, wherein the circular outer supporting piece is made of a composite carbon fiber material.

3. The method of claim 1, wherein the circular inner supporting piece is made of a composite foam material.

4. The method of claim 1, wherein the reinforcement piece is made of a composite carbon fiber material.

5. The method of claim 1, wherein the step of shaping the assembly and the second carbon fiber layers includes: placing the assembly and the second carbon fiber layers into a mold cavity; vacuuming the mold cavity; injecting a mold material into the mold cavity; and heating the mold material.

6. The method of claim 1, wherein each of the first and second carbon-fiber yarns includes a plurality of carbon fibers.

7. The method of claim 1, wherein the circular inner supporting piece is centripetally tapered in shape.

8. The method of claim 1, wherein the circular reinforcement piece is centripetally tapered in shape.

9. The method of claim 1, wherein the circular engaging groove has an circular tire-mounting opening that corresponds to the circular trench, and an internal space that is formed by the removal of the outer supporting piece and that has a maximum width greater than a maximum width of the tire-mounting opening.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) Other features and advantages of the disclosure will become apparent in the following detailed description of the exemplary embodiment with reference to the accompanying drawings, of which:

(2) FIG. 1 is a schematic flow chart illustrating a conventional method for making a carbon fiber wheel rim;

(3) FIG. 2 is a schematic side view, illustrating that the conventional carbon fiber wheel rim is formed by attaching carbon fiber fabrics onto an airbag;

(4) FIGS. 3 to 5 are schematic perspective views of the exemplary embodiment according to the present disclosure, illustrating consecutive steps of a method for making a wheel rim;

(5) FIG. 6 is a schematic flow chart of the exemplary embodiment, illustrating sectional views in the consecutive steps of the method; and

(6) FIG. 7 is a sectional view of the wheel rim that is made by the method of the exemplary embodiment according to the present disclosure; and

(7) FIG. 8 is a flow chart of the exemplary embodiment, illustrating the consecutive steps thereof.

DETAILED DESCRIPTION

(8) Referring to FIGS. 3 to 8, the exemplary embodiment of a method for making a carbon fiber wheel rim, which has a circular engaging seat 21 formed with a circular engaging groove 22 (see FIG. 7) for engagement with a tire (not shown), includes steps as follows:

(9) Step 101: preparing a circular outer supporting piece 20 (see Section (a) of FIG. 3). The circular outer supporting piece 20 is made of a material having superior hardness and being susceptible to heat, such as a composite carbon fiber material. As shown in FIG. 6, the circular outer supporting piece 20 has a cross-section profile that is complementary in shape to the circular engaging groove 22.

(10) Step 102: winding continuously and circumferentially at least one first carbon-fiber yarn 30 around the circular outer supporting piece 20 to form a plurality of first carbon fiber layers (see Sections (b) and (c) of FIG. 3). In this embodiment, the first carbon-fiber yarn 30 includes a plurality of carbon fibers, and each of the first carbon fiber layers is formed by winding the first carbon-fiber yarn 30 around an outer surface of the circular outer supporting piece 20 in a mutually-different winding angle. The circular outer supporting piece 20 and the first carbon fiber layers constitute an engaging seat preform 31.

(11) Step 103: connecting a circular inner supporting piece 40 to the engaging seat preform 31 (see Section (a) of FIG. 4). In this embodiment, the circular inner supporting piece 40 is attached to an inner side of the circular outer supporting piece 30 and is concentrically arranged with respect to the engaging seat preform 31. The circular inner supporting piece 40 may be made of a light-weight material that is susceptible to heat, such as a composite foam material. As shown in FIG. 6, the circular inner supporting piece 40 is centripetally tapered in shape and has a substantially trapezoidal cross-section.

(12) Step 104: connecting a circular reinforcement piece 50 to the circular inner supporting piece 40 oppositely of the engaging seat preform 31, so that the engaging seat preform 31, the circular inner supporting piece 40 and the reinforcement piece 50 constitute an assembly (see Section (b) of FIG. 4). In this embodiment, the reinforcement piece 50 is attached to an inner side of the circular inner supporting piece 40 and is arranged concentrically with the circular inner supporting piece 40 and the engaging seat preform 31. As shown in FIG. 6, the reinforcement piece 50 of this embodiment is centripetally tapered in shape and has a substantially triangular cross-section, where an inner corner of the same distal from the inner supporting piece 40 is substantially rounded. The reinforcement piece 50 may be made of a material having superior hardness and being susceptible to heat, e.g., a composite carbon fiber material.

(13) Step 105: winding continuously and circumferentially at least one second carbon-fiber yarn 32 around the assembly to form a plurality of second carbon fiber layers (see Section (c) of FIG. 4). In this embodiment, the second carbon-fiber yarn 32 includes a plurality of carbon fibers, and each of the second carbon fiber layers is formed by winding the second carbon-fiber yarn 32 around a circumferential surface of the assembly in a mutually-different winding angle.

(14) Step 106: fixing the assembly with the second carbon fiber layers to form an outer frame preform 33 on the assembly (see Section (a) of FIG. 5). The outer frame preform 33 has an annular outer surface that is distal from the circular reinforcement piece 50. In this embodiment, Step 106 may be conducted by: placing the assembly together with the second carbon fiber layers into a mold cavity; vacuuming the mold cavity; injecting a mold material (such as a thermosetting resin material) into the mold cavity; and heating the mold material so as to obtain the outer frame preform 33.

(15) Step 107: cutting the outer frame preform 33 and the engaging seat preform 31 from the annular outer surface of the outer frame preform 33 to form a circular trench 23, followed by removing the circular outer supporting piece 20 from the circular trench 23 to form the circular engaging groove 22 of the circular engaging seat 21 and an outer frame 33 which covers the circular engaging seat 21, the inner supporting piece 40 and the reinforcement piece 50 (see Section (b) of FIG. 5 and FIG. 6). In this embodiment, the circular engaging groove 22 has a circular tire-mounting opening 23 that corresponds to the circular trench 23, and an internal space that is formed by the removal of the outer supporting piece 20. The internal space has a maximum width (W2) that is greater than a maximum width (W1) of the tire-mounting opening 23 (see FIG. 7).

(16) As illustrated in FIG. 7, the wheel rim obtained by the method of the exemplary embodiment includes the circular engaging seat 21, the circular inner supporting piece 40, the reinforcement piece 50 and the outer frame 33. The circular engaging seat 21 is configured to have a substantially U-shaped cross-section and is formed with the circular engaging groove 22. As aforementioned, the circular engaging seat 21 is made by winding the first carbon-fiber yarn 30 into the first carbon-fiber layers. The circular inner supporting piece 40 is attached to the inner side of the circular engaging seat 21 and is concentrically arranged with respect to the circular engaging seat 21. The circular inner supporting piece 40 may be made of a light-weight material that is susceptible to heat, such as a composite foam material. As shown in FIG. 7, the circular inner supporting piece is centripetally tapered in shape and has a substantially trapezoidal cross-section. The reinforcement piece 50 is attached to the inner side of the circular inner supporting piece 40 and is arranged concentrically with the circular inner supporting piece 40 and the circular engaging seat 21. As shown in FIG. 7, the reinforcement piece 50 of this embodiment is centripetally tapered in shape and has a substantially triangular cross-section. The reinforcement piece 50 may be made of a material having superior hardness and being susceptible to heat, e.g., a composite carbon fiber material. The outer frame 33 cooperates with the circular engaging seat 21 to encapsulate the circular inner supporting piece 40 and the reinforcement piece 50. As aforementioned, the outer frame 33 is formed by winding the second carbon-fiber yarn 32 into the second carbon-fiber layers.

(17) Since the circular engaging seat 21 and the outer frame 33 of the exemplary embodiment according to the present disclosure are formed by continuous winding of the first and second carbon-fiber yarns 30, 32 into the first and second carbon fiber layers, such winding can be performed by machine instead of manpower. As such, the production time and cost can be greatly reduced. Moreover, the wheel rim made by the method of the present disclosure has a uniform structural strength distribution owing to the continuous winding structure of the first and second carbon-fiber yarns 30, 32. Furthermore, the winding of the first and second carbon-fiber yarns 30, 32 provides a relatively small amount of gaps formed therebetween and may result in relatively less bubbles generated during the fixing step (i.e., Step 106) and improved production yield. Even further, the outer frame 33 is integrally formed as one piece to cover the circular engaging seat 21, the circular inner supporting piece 40 and the reinforcement piece 50, thereby further improving the overall structural strength of the wheel rim according to the present disclosure. Even further, the method of the present disclosure does not require utilization of an airbag, so that the overall process can be further simplified and accelerated.

(18) While the disclosure has been de scribed in connection with what is considered the exemplary embodiment, it is understood that this disclosure is not limited to the disclosed embodiment but is intended to cover various arrangements included within the spirit and scope of the broadest interpretation so as to encompass all such modifications and equivalent arrangements.