专利摘要:
rim base with integrated flange, made of materials composed of fibers, as well as a process for its production. the invention relates to a rim base (15) with an integrated flange (14), made of material made up of fibers, as well as a process for its production. the flange is then formed by protrusions, directed inward, of layers of fibers (9a) from the base of the rim, with the layers of fibers entering the base of the rim into the flange without interruption of fiber. production takes place by laying fiber material on a molding tool (4) corresponding to the outline of the rim base, which has a radially continuous or segmented groove (10a). the fibers are then so laid that the fibers of at least one layer of fibers have protrusions directed towards the groove. preferably a multi-part molding tool is used, which allows a reduction in the groove width and thus a deformation of the protrusions.
公开号:BR112014013054B1
申请号:R112014013054-0
申请日:2012-12-03
公开日:2020-09-01
发明作者:Jens Werner;Christian Köhler;André Bartsch;Sandro Mäker;Michael Dressler;Martin Lepper;Werner Hufenbach
申请人:ThyssenKrupp Carbon Components GmbH;
IPC主号:
专利说明:

[001] This refers to the use of lightweight construction materials in the construction of vehicles, especially in the production of spare parts and adjustment, is known from the state of the art. Especially the use of light metals such as aluminum and magnesium for small and body parts has been proven, in the meantime, also in series production. In addition, fiber composite materials are increasing in importance due to their outstanding weight and mechanical properties. Until now, these composite materials are, however, predominantly used in the construction of bodies, since the production of components subject to load, such as, for example, plastic rims composed of fibers, is expensive and remains the subject of current research.
[002] The use of fiber composite materials for vehicle wheels or rims leads to clear improvements in relation to the acceleration and running behavior of a vehicle. The reduction in the inertia and inelastic mass of the wheels simultaneously results in better vehicle performance on the roads as well as a marked reduction in support forces and can then, for example, result in longer life of shock absorbers, suspension of mandrel wheel and bearings.
[003] From the state of the art, lightly built vehicle wheels are already known, consisting entirely or at least partially of material composed of fibers.
[004] DE 41 23 459 C1 describes a vehicle wheel, consisting of a plastic rim and a wheel disk consisting at least partially of metal, as a considerable reduction in weight and at the same time sufficient thermal conductivity of the wheel can be obtained compared to conventional steel rims. The inner side of the rims, which consists of a highly resistant plastic with relatively high thermal conductivity, is then built between a safety base and a deep one as an ideal counterpart to the wheel disc, so that both abut widely together positive. In addition, on the side of the deep base opposite the tire, an inwardly directed or continuous discontinuous edge may be arranged for screwing the wheel disc. According to this document, another positive and material union is provided between the rim and the wheel disk. In order to favor a union by material, it is especially preferred to form a wheel disc and rim of a metal-plastic compound. The use of fiber composite materials is not described in this document.
[005] DE 20 2005 004 399 U1 describes a vehicle wheel consisting of a fiber-reinforced plastic rim and a metal wheel wrench. The wheel wrench or spokes or other connecting elements are centrally connected with the rim, being guided through the rim. In comparison with fixing the wheel wrench to an edge on the inside, as in DE 41 23 459 C1, this solution must be advantageous. This would apply especially to power-wheel tires, because due to the central fixation, unilateral stresses are supposed to be avoided mechanically by strongly requesting the rim. Furthermore, the problem would be addressed in such a way that, according to the state of the art, no hoops would be produced with an internally located edge, uniformly reinforced with fiber.
[006] With DE 10 2010 010 513 A1 and DE 10 2010 010 512 A1, processes are described for the production of hollow profile components, especially wheel rims, of materials composed of fibers, by laying fibers by braiding technique on a molding tool reproducing the contour of the component and subsequent consolidation of this preform with matrix material. In addition, it is described as a second component, especially a wheel disk or wrench or a wheel cross, during the laying of the fibers it can be integrated in a positive union in the preform, to establish a firm union with the same when subsequent consolidation by union by material. Thus, in fact, a high-strength joint of the wheel wrench and rim is guaranteed, which, however, is based on a non-detachable union of both components and thus makes possible a modular structure of vehicle wheels by combination various wheel disks and rims.
[007] US 3,917,352 describes a fiber-reinforced plastic vehicle wheel as well as a process for its production. The wheel is then formed in one piece and comprises both a rim bed and a wheel disk. The production of the wheel occurs by wrapping a flexible fabric tube around the two halves of a molding tool, and by over-winding a groove the wheel disk can be formed. The laying of fibers when winding occurs, however, not sufficiently by positive union; therefore, the flexible fabric tube must be additionally wrapped with a fabric strap or filaments. Due to the restriction of the production process to rims in one piece, a modular structure of vehicle wheels is not possible.
[008] DE 42 23 290 B4 describes a composite synthetic resin wheel, which consists of several partial castings. The partial castings have corresponding threads in their joining areas, so they can be joined by screwing. This type of joint, which differs from the industrial standard, requires the backing of the threads even when producing the partial casting parts and, thus, severely limits its viability of use. The production of partial parts with these threads, moreover, is not readily possible without a casting or injection molding process.
[009] Lightweight construction wheels made of fiber composite materials are so far more niche products and often prohibitive for the average consumer due to the small number of units and high manufacturing costs. This is mainly due to the fact that for the production of hoops made of fiber composite materials, not only technical knowledge is needed, but also special machines and technologies, which are only slowly introduced in series production. The introduction of this technology in the mass market could, however, be essentially facilitated by modular systems, which allow different manufacturers to resort to a selection of basic elements and their individualization.
[0010] The objective of the present invention is to overcome the disadvantages of the state of the art and to provide a rim base with an integrated flange of material composed of fibers for the firm connection with a wheel disc or wheel center, as well as a process for their production. This rim base must be individualized at will as a basic element by mounting a visually attractive wheel disc on the integrated flange. The rim base must be able to be complemented by fixing the wheel disk to the integrated flange for a full-load vehicle wheel, especially with access to highways.
[0011] The rim base according to the invention consists entirely of material composed of fibers and has, on the inside or on the side of the rim base opposite the tire, a flange for fixing a wheel center or a disc wheel. The rim base is bilaterally limited by rim tips and has a deep rim base between the rim tips, in which region the rim base has the smallest periphery. The rim base may have other designs, for example, protrusion or rim of the rim, which, however, are of secondary significance to the present invention. According to the invention, the flange can be arranged in the entire region of the base of the rim, the flange being preferably disposed in the deep base of the rim.
[0012] Ring base and flange are formed, preferably in one piece, of material composed of fibers. The fiber composite material preferably consists of reinforcement fibers, which are embedded in a duraplastic or thermoplastic matrix material. In one piece, this means that the base of the rim and flange are formed at least partially from common reinforcement fibers. Due to the presence of reinforcing fibers common in the rim and flange base, forces, especially tensile forces, are transmitted, above all, between the rim base and flange.
[0013] As reinforcement fibers, preferably carbon, glass or aramid fibers are used. The reinforcement fibers are then laid in layers of fibers in a stratified form on the base of the rim and flange. Depending on the production process, the fiber layers may then consist of a mesh, fabric, mesh or talag. Preferably, the fiber layers are formed of endless fibers, especially interlaced or rolled. The layers of fibers formed of endless fibers present a mutual transition at points of inversion, in which the direction of the fiber layers takes place. The inversion points are preferably located on the periphery of the rim base in an axial direction, especially at the ends of the rim.
[0014] The rim base formed in this way in several layers of fibers has at least one layer of fibers with a protuberance directed inwards. These protuberances form, in the consolidated form, the flange serving to fix the wheel disc. The fiber layers then, according to the invention, enter without interruption from the rim base to the flange. The structure of the flange and rim base of layers of common fibers or fibers thus results in a rim base with an integrated high strength flange, with the forces and moments acting on the flange being transmitted optimally to the rim base.
[0015] Preferably, the layers of fibers enter and again leave the flange and have an inversion point at their lower end. In it a reversal of direction of the fiber layer takes place, especially of the fibers in the fiber layer. Due to the uninterrupted course of the fiber layers, the flange, especially at its lower end, gives greater stability compared to a multi-layer sandwich construction. Particularly preferably, the fiber layers are formed of fibers without end, whereby at the lower end of the flange the endless fibers have a point of inversion. In it, however, no layer of fibers has a mutual transition; on the contrary, a reversal of direction of a layer of fibers takes place.
[0016] Particularly preferably, the fiber layers pass through the entire rim base as well as the flange without interruption. Thus, a layer of fibers, starting from a rim end, passes through the center of the rim towards the entire rim base, enters especially without interruption in the flange and again leaves it and continues to the other end of the rim. Layers of fibers formed of endless fibers still present mutual transition at points of inversion, which are found at the periphery of the rim base, especially at the axially most extreme points of the rim base, the rim tips. Thus, a layer of fibers, starting from a rim end, towards the center of the rim, crosses the entire base of the rim, enters and exits the flange continuously and continues to the other end of the rim. There, the fiber layer presents an inversion point, in which it transitions to a fiber layer, as a rule, radially seated over it. This then runs in the opposite direction to the center of the rim, enters and exits again without interruption at the flange and continues to the first rim end.
[0017] Preferably still, a part of the fiber layers crosses the base of the ring only partially. That is, at least one layer of fibers does not completely cover the base of the rim, especially in an axial direction. This layer of fibers, starting from a point between the two ends of the rim, passes through the center of the rim towards the center of the rim. The fiber layer then enters the flange at least without interruption, and preferably without interruption leaves it again. Entering and exiting the flange, the fiber layer, starting from any end on one side of the flange, crosses towards the flange a part of the base of the ring, enters the flange without interruption and leaves it again, to any other point in the other side of the flange. Layers of fibers supplied with endless fibers, which show mutual transition at points of inversion, then present points of inversion in the region of the base of the rim. The positioning of the points of inversion of these layers of fibers then occurs in regions of the base of the rim that are particularly requested, as expected, especially in the region close to the flange. Due to the positioning of the points of inversion of the fiber layers within the base of the rim and not exclusively in the region of the ends of the rim, certain regions of the base of the rim extended in axial direction can be furnished with layers plus layers of fibers formed of endless fibers than the entire base of the rim. This or the partial lining of parts of the base of the rim with layers of unformed fibers of endless fibers leads to a relatively greater layer thickness of the fiber material in these regions. Due to the subsequent deposition of fiber layers with inversion points in the region of the rim ends over the entire base of the rim, all fiber layers are integrated into a firm layered compound.
[0018] In the ring base according to the invention, the protrusions of the fiber layers directed inwards are arranged in such a way that the flange formed therefrom is presented in a continuous or interrupted manner, in the form of individual circle segments on the inner side the base of the rim. In the case of individual circle segments, they can be formed distinctly and have a particularly distinct radial extension, in order, for example, to allow the application of wheel centers with hollow spokes of different length. Also with a continuous flange it is preferred to vary the contour and height of the flange along its periphery.
[0019] The layers of fibers formed of fibers, entering the flange, preferably entering and leaving, are the layers of fibers forming the flange of the rim base according to the invention. The ring base according to the invention preferably has at least one layer of fibers, preferably at least two and still preferably at least three layers of fibers. In the fiber layers forming the flange, it is preferably a number of mutually subsequent fiber layers, located radially internally, including the radially innermost. The greater the number of fiber layers forming the flange, the greater the resistance of the flange thus formed and the better the introduction of force on the remaining rim base.
[0020] The base of the rim according to the invention additionally has a layer of fiber layers forming the base of the rim, which are arranged exclusively in the region of the base of the rim and have no protrusions. These layers advantageously cover or overlap the protrusions of the fiber fiber layers forming the flange and are thus responsible for an uninterrupted transfer of force in the region of the base of the rim. Preferably, in the layers of base forming fibers of the ring, a number of mutually subsequent layers of fibers are located radially externally, including the radially outermost.
[0021] The layers of fibers forming the base of the ring, just like the layers of fibers forming the flange, are oriented outside the protuberances, by segments, preferably with approximately constant distance to the axis of rotation symmetry, regardless of the regions of the rim, protrusion or shoulder of the rim. This orientation advantageously allows the execution of a highly resistant frame base, reinforced with fibers. Within the inwardly protruding protrusions, the fiber layers forming the flange are preferably oriented in an approximately radial direction from the base of the rim. This makes possible an optimum force conduction of the forces transferred by the wheel hub through the wheel disc to the flange. Correspondingly, a transition of the orientation of the layers forming the flange takes place when entering the region of the flange. This ensures, at the same time, the highly resistant connection of the flange to the rim base as well as optimum shape conduction of the forces transferred on the flange to the rim base and vice versa.
[0022] Regarding the orientation of the fibers within the individual fiber layers, it can vary between different fiber layers. Preferably, the fibers present in the fiber layers forming the base of the ring an angle with respect to the axial direction of the base of the ring different from that of the fibers of the layer forming the flange. The fiber orientation of the fiber layers forming the base of the rim is, above all, determined by the desired mechanical properties for the base of the rim. The fiber direction of the fiber layers forming the flange serves to provide a highly resistant flange with an optimal transfer of force to the base of the rim.
[0023] Furthermore, preferably, the adaptation of the fiber course in the different layers of the rim base according to the invention occurs in correspondence to the mechanical loads to be expected. The adaptation is then done, predominantly, by adjusting the orientation of the fibers, by adapting the layer thickness as well as possibly by introducing additional textile inserts between the fiber layers at particularly requested points, as expected.
[0024] The fibers of the fiber layers forming the flange have a fiber angle of ± 3 ° to ± 87 °, preferably ± 15 ° to ± 65 ° and more preferably ± 20 to ± 60 ° with respect to the axial direction of the rim base. When using textile semifinished products, the fibers can also have angles of ± 0 to ± 90 °, preferably ± 3 to ± 87 °. Larger fiber angles should therefore be particularly preferred, since fiber layers with fibers so oriented can immediately form a flange of any desired shape. With fiber angles that are too large, however, there is a disadvantage that there is an uneven distribution of fibers in the region of the flange, especially in the region of entry and exit of the fibers.
[0025] The fibers of the fiber layers forming the base of the ring have a fiber angle of ± 3 ° to ± 87 °, preferably ± 20 ° to ± 75 ° and even more preferably ± 30 ° to ± 70 ° with respect to axial direction of the rim base. When using textile semifinished products, the fibers can also have angles of ± 0 to ± 90 °, preferably ± 3 to ± 87 °. The transmission of torques from the hub to the tires requests the rims smaller than shear and bending stresses in curved gears or strikes for impact in holes or strikes of the impact type, such as when the rim is hit against a sidewalk. These impulse-type stresses can be transferred particularly well by means of a fiber alignment practically parallel to the axial direction of the rim base and bypassed to the wheel hub or suspension. The preferred fiber alignment according to the invention within the fiber layers forming the base of the rim is, therefore, a compromise with respect to the multifaceted character of the demands acting on a vehicle wheel. Even better stability of the rim is preferably achieved by the fact that the fibers of different fiber layers have divergent orientations.
[0026] In addition, the flange has an insert in the protrusions of the fiber layers directed inwards. These inserts also appear as an interrupted circle ring, that is, almost continuously with one or more interruptions, or as individual circular circle segments. Thus, it is advantageous to obtain a mechanical reinforcement of the entire flange or individual regions, such as at the subsequent points of application of the wheel center. The inserts preferably have threaded sleeves or bushings, which are used to later fix the wheel disc or wheel center, eg by screwing. The fixing can take place, in a particularly advantageous way, by lowering the fixing means in the insert, so that they do not protrude from the flange bilaterally. As a result, the wheel disk or wheel center can be fixed advantageously without any visible external fixing means. Preferably, the inserts consist of plastic, foam, material composed of consolidated fibers, matrix material or metallic materials.
[0027] The flange preferably has a rectangular cross-section geometry with straight flanks or a U or V-shaped geometry with inclined flanks. The flanks can then have either an essentially radial alignment or also a divergent alignment, eg slightly angled inward or outward. In principle, a plurality of cross-sectional geometries is feasible, the flank being preferably formed as an ideal counterweight to application elements, which are found in the wheel disc or wheel center. The edges of the flange are preferably formed rounded to improve the mechanical properties of the base of the rim, especially with regard to the notching effect, and to minimize the disk of sharp edge injuries. In another preferred embodiment, the flange's cross-sectional geometry varies along its periphery so that, for example, it can be adapted to the application elements distinctly formed from individual hollow radii.
[0028] A process for producing a frame base with an integrated plastic flange made of fibers is also the object of the invention.
[0029] According to the invention, a molding tool corresponding to the contour of the rim base to be produced is used, which is provided with a continuous or segmented radial groove. The fiber material settles on this molding tool in such a way that the fibers are laid by a positive bond on the molding tool and the fibers of at least one layer of fibers enter the groove without interruption. In this way, a preform of the rim base is obtained, which has at least one layer of fibers with protrusions directed inwards. Particularly preferably, the fibers are so placed with positive bonding on the molding tool that fibers from at least one layer of fibers enter and exit the groove without interruption. Upon subsequent consolidation of the preform by infiltration of a matrix material and compression in a suitable external tool, the rim base according to the invention is produced. By consolidating the protuberance of at least one layer of fibers, the flange according to the invention is formed, directly attached to the base of the rim in a highly resistant manner.
[0030] The laying of the fiber material on the shaping tool occurs in the process according to the invention by draping flat multi-axial structures, cut pieces of flat structures or layers of fabric on the shaping tool, by rolling the tool molding with ribbon interlacing or round interlacing compressed in plane and / or by braiding the molding tool with braided threads.
[0031] Particularly preferred is the laying of the fiber material, for example, the production of the preform, by braiding the molding tool with the aid of a radial braiding machine. The shaping tool is covered as a braiding core by means of multiple back and forth movements by the coaxial braiding machine with the desired number of layers of fibers consisting of endless fibers. The yarn tension of the braided fibers is so adapted that they are seated on the molding tool with positive bonding. It is also possible to adjust the angle of the braided wire as well as the union of vertical threads extending in a radial direction. Thus, as well as by specific adjustment of the inversion points of the round-trip movement, preforms can be produced specifically with locally varying properties, especially fiber orientation and plaiting thickness. These preforms can be produced by consolidating rim bases with fiber travel adapted to the mechanical or thermal loads to be expected.
[0032] When the shaping tool is entwined or wound, the tension of the thread is so adjusted that the endless fibers of the fiber material of at least one layer of fibers when the interlacing of the groove enters and leaves it again. no interruptions. With this, a woven body is laid on the molding tool, which has at least one layer of fibers with a protrusion directed into the groove. The adjustment of the thread tension then allows the control of the flank angle of this protuberance, being that a greater thread tension, as a function of the laying angle, leads, as a rule, to a protuberance with a more inclined flank angle, and a lower wire tension to a protuberance with a flatter flank angle. However, fibers cannot be laid on a rectangular groove by braiding technique even with high wire stresses so that they completely touch the internal contour of the groove; for this purpose, a groove is provided with inclined sides, for example a wedge-shaped groove. In addition, when laying fibers with a very small angle to the axial direction of the base of the ring, a small thread tension can also be advantageous, allowing the formation of a reserve of thread forming the protuberance. In the process according to the invention, the wires are tensioned with a force of 0.7 N to 9 N, preferably with a force of 1 N to 7 N and especially preferably with a force of 2 N to 5 N.
[0033] In addition to the thread tension, also the angle of laying of the fibers when the shaping tool is entwined or wound is important for the formation of the flange. The laying of the fibers in the axial direction of the base of the ring would have the consequence that the execution of sufficiently large protuberances would be problematic even with high thread tension. When laying endless fibers transversely to the axial direction of the base of the ring, entanglement or winding could occur, on the contrary, with very high thread tension, since endless fibers could be laid without problem in the continuous groove. However, it is precisely in the flange edge regions that fiber slips could occur, resulting in an uneven distribution of fibers in the flange region. In the process according to the invention, therefore, an appropriate combination of wire tension and laying angle must be selected, with which the molding of sufficiently large flanges with uniform fiber distribution can be carried out.
[0034] The molding tool used in the process according to the invention is preferably a molding tool in several parts, the individual mold parts of which are axially displaceable with each other. The radially continuous or segmented groove is preferably formed by a notch, limited in axial and radial direction, between the mold parts, the width of which is adjustable by axial displacement of the mold parts between them.
[0035] In a preferred form of execution of the process, a molding tool is used in several parts, which has a radial division with a notch located therein with a shape of approximately rectangular cross section or flanks approximately perpendicularly directed inward. When using a molding tool of this type, the laying of one or more layers of fibers on the protrusion initially leads to the formation of one or more protrusions directed inwards, which overlap the groove in wedge shape and only partially touch the internal contour.
[0036] In addition, the notch width is preferably adjustable by axial displacement of the mold parts of the molding tool in various parts. By the axial displacement, subsequent to the laying of the fibers, of the mold parts of the molding tool in several parts, the width of the notch or groove is then reduced, with which the protuberances located there are transformed, similar to that of a stamping. After deformation, the protrusions advantageously touch completely and with a positive union in the internal contour of the groove then narrowed. Thus, the protrusions are advantageously brought to a shape of the flange close to the final contour by the axial displacement of the mold parts of the molding tool. Particularly advantageously, the endless fibers are oriented in the region of the protuberances after deformation in an approximately radial direction from the base of the rim. By the continuous transition from the orientation of these fibers to the orientation of the fibers forming the base of the rim along the periphery of the base of the rim, both from the radially inner layer as well as from the radially outer layer, thus allowing the introduction and transfer of optimum force between the wheel rim and wheel or wheel center.
[0037] In an equally preferred embodiment of the process, a multi-part molding tool with a notch having a cross-sectional shape approximately in the form of a wedge or with inwardly directed flanks is employed. When using a molding tool of this type, the laying of one or more layers of fibers on the indentation causes them to form one or more protuberances directed inwards, which completely touch the internal contour of the indentation. As the layers of fibers fully follow in a positive union the course of the molding tool including the notch, the protrusions have a recess on their surface corresponding to the internal contour of the notch. In a particularly preferred embodiment, this recess is compensated by inserting inserts, which are adapted to the internal contour of the notch. These inserts can be either in the form of an interrupted circle ring, for example, as a retaining ring, or as individual circle segments.
[0038] The molding tool employed in the process according to the invention preferably has additionally circle segments, which are located in the notch located between the different mold parts. The dimensions of the notch are then determined in axial direction by the mold parts of the axially displaceable mold tool and in radial direction by the contour of the radially displaceable circle segments. Thus, the width of the notch is adjustable by axial displacement of the mold parts and the height by radial displacement of the circle segments. In addition, the circle segments can be removed from the notch when it is widened by axial displacement of the mold parts. When the circle segments of the notch are removed, the shape and dimension of the notch are again determined only by the mold parts. Preferred is also the safety of the circle segments in the notch located between the mold parts by axially movable sliding parts. This makes it possible to remove the circle segments even without increasing the width of the notch, just by unlocking the sliding parts. The sliding parts are, moreover, preferably so deformed that by fixing them on the outside of one of the mold parts, the dimension of the notch can be determined and, thus, the deformation of the protuberances close to the final contour.
[0039] In another preferred embodiment of the process according to the invention, the notch contains circle segments with a surface contour approximately in the form of a wedge or flanks extending in the shape of a wedge. The laying of one or more layers of fibers on top of the protrusion and circle segments causes them to form one or more protuberances, which completely touch the inner contour of the circle segments. Then, the circle segments are removed, either by increasing the width of the notch by axially displacing the mold parts or by disengaging the locking of the circle segments by axial displacement of the sliding parts. Once the circle segments are removed, by axial displacement of the mold parts, the width of the notch is reduced and the protuberances found there are transformed. After the deformation, the protuberances advantageously touch completely and by positive union, in the internal contour of the narrowed notch.
[0040] By the controlled laying of the fibers on the surface of the circle segments as well as by the subsequent deformation of the protuberances close to the final contour, a flange with particularly homogeneous fiber distribution and a fiber volume content is obtained after consolidation very high. The fiber volume content of the rim base flange according to the invention then amounts to at least 40%, preferably particularly at least 50% and more, preferably at least 60% and more and particularly preferably 90%. As a result, the flange advantageously has particularly homogeneous properties with respect to mechanical or thermal stresses and especially few weak points or impurities. The positive joining of the fibers on the surface of the circle segments makes it possible, together with the deformation of the protrusions, in a particularly advantageous way, to make a very precise adjustment of the fiber orientation on the flange as well as in its transition region to the base of the rim .
[0041] In another preferred embodiment of the process according to the invention, circle segments with an approximately flat internal contour are in the notch. The laying of one or more layers of fibers over the notch and circle segments causes them to completely touch the flat surface of the circle segments, ending with the remaining rim base. Then, the circle segments are removed, either by increasing the notch or, preferably, by unlocking by axially displacing the sliding parts. The fiber layers now extending flat through the notch are then compressed into the enlarged notch by means of punching segments. By the axial displacement of the mold parts, the notch width is then reduced and the protrusions deformed. After deformation, the protrusions abut completely and positively against the internal contour of the now narrowed groove.
[0042] It is also preferred to combine the transformation of the protuberances by axial displacement of the mold parts and the insertion of inserts in the protuberances. The insertion of the inserts can then advantageously serve to stretch or align the fiber layers forming the flange with each other before deformation of the protuberances. In particular, the puncture segments already mentioned can remain on the protrusions after compressing the fiber layers into the indentation as inserts.
[0043] Preferably, after the narrowing of the notch and deformation of the protuberances or after the insertion of the inserts in the protuberances, other layers of fibers are laid on the base of the rim. Since the notch is now completely filled by deformed protrusions from previously laid fiber layers or by layers of fibers and inserts, the newly laid fiber layers do not form protrusions over the notch. Thus, these layers of fibers preferably form a second layer, whose layers of fibers are seated only in the region of the base of the ring and whose endless fibers do not enter the flange. With this, they cover or overlap the open protuberances above the first layer located radially below, which leads to an improvement in the stability of the rim base. After depositing the second layer of fiber layers forming the ring, the molding tool is opened by axial displacement of the mold parts and the ready preform is removed.
[0044] It is also preferred to lay layers of fibers, both forming a flange and also forming a rim base, in axially limited regions of the rim base. These layers of fibers pass through the base of the rim, therefore, only in part. The laying of these layers of fibers can occur by applying additional layers of fibers in the form of textile inserts, for example, pieces cut from flat textile structures or a fabric belt. Equally preferred is the laying of these layers of fibers formed of endless fibers, for example, by braiding or wrapping, by adjusting inversion points at any point on the base of the rim, especially at points on both sides of the flange. It is preferred to lay these additional fiber layers on the flange and in the region close to the flange, both for flange formation (flange forming fiber layers) and for flange overvoltage (flange forming fiber layers). In both cases, the laying of these fiber layers advantageously produces a reduction of the notch effect on the flange region.
[0045] The consolidation of the preform then occurs, preferably with the aid of an external tool, preferably metallic and in several parts. Most preferably, consolidation of the preform takes place in an RTM process. In any case, the external tool has a chamber corresponding to the shape of the preform, in which the preform is inserted. In the external tool equipped with the preform, appropriate matrix material is then injected under a specific pressure and at a specific temperature. With the hardening of the matrix material, the preform is consolidated to the finished rim base. Execution examples
[0046] The invention will be explained below based on four examples of execution.
[0047] They then show:
[0048] Figure 1: the laying of fiber layers in a multi-part molding tool with increased notch by means of a radial plaiting machine,
[0049] Figure 2: a first layer of layers of fibers forming flanges with protrusions directed inwards in a molding tool in several parts with increased notch,
[0050] Figure 3: a first layer of layers of fibers forming a flange with deformed protuberances in a tool, demolding in several parts with reduced notch,
[0051] Figure 4: the laying of a second layer of fiber layers forming a rim without protrusions directed inward in a molding tool in several parts with reduced notch and layers of fiber forming flange seated on it with deformed protuberances located in the notch,
[0052] Figure 5: a perspective view of the air base according to the invention with integrated flange,
[0053] Figure 6: a cross section of the rim base according to the invention with integrated flange,
[0054] Figure 7: a cross section of the rim base according to the invention with detailed representations of the flange,
[0055] Figure 8: the laying of a first layer of layers of fibers forming flanges with protrusions directed inwards in a molding tool in several parts with fixed notch by means of a radial plaiting machine,
[0056] Figure 9: the laying of a second layer of fiber layers forming a rim without protrusions directed inwards in a first layer of fiber layers with an integrated insert in its protuberances,
[0057] Figure 10: the laying of both fiber layers forming the rim base as well as the flange with inversion points in the region of the rim base, especially in the region close to the flange,
[0058] Figure 11: the laying of a first layer of layers of fibers forming flange with protrusions directed inwards in a molding tool in several parts with enlarged notch and circle segments located there by means of a radial plaiting machine,
[0059] Figure 12: the radial withdrawal of the circle segments from the notch increased by axial displacement of the mold parts,
[0060] Figure 13: the laying of a second layer forming a ring of fiber layers without protrusions directed inwards in a molding tool in several parts with reduced notch and layers of fibers forming flange seated there with deformed protuberances located in the notch,
[0061] Figure 14: The laying of a first layer of fiber layers forming flanges with protrusions directed inwards in a multi-part molding tool with enlarged notch and circle segments located there and sliding parts by means of a braiding machine radial,
[0062] Figure 15: a first layer of layers of fibers forming a flange without protrusions directed inwards in a molding tool in several parts with enlarged notch and circle segments located there and sliding parts,
[0063] Figure 16: the compression of a first layer of layers of flange-forming fibers into the enlarged notch of a molding tool in several parts without circle segments located there by means of punching segments,
[0064] Figure 17: a first layer of fiber layers forming flange with deformed protuberances in a molding tool in several parts with reduced notch,
[0065] Figure 18: laying of a second layer of fiber layers forming a rim without protrusions directed inwards in a molding tool in several parts with reduced notch and layers of fiber forming flange seated there with deformed protuberances, located in the notch,
[0066] Figure 19: a textile fitting, seated on a molding tool in several parts with reduced notch and layers of fibers forming flange seated there with deformed protuberances, located in the notch. Execution example 1
[0067] The multi-part molding tool 4, shown in Figure 1, features a first mold part 6 and a second mold part 7, which are axially displaceable with each other. Between the two mold parts 6, 7, the molding tool has a rectangular notch 10a, radially continuous, with flanks 4a and bottom 4b. Corresponding to the axial position of both mold parts 6, 7 displaceable along the direction of travel 5, the notch 10a has a width a.
[0068] The shaping tool 4, when producing a rim base according to the invention, serves as the braiding core of a radial braiding machine 1. Through it the shaping tool 4 is moved axially back and forth along the axis of rotation symmetry 11, with braided threads 3 wound by 2 radial braiding bobbins, directed to the braiding point, are seated on the shaping tool 4. By the mutually crossed movement of the bobbins 2 along two sinusoidal bobbin lines intersect and mutually intercept the braid threads 3 running from the bobbins 2 to the molding tool 4. Thus, a braid of fibers 8 is placed on the braiding core in a positive union, with an individual fiber layer it is respectively seated during a round-trip motion of the molding tool 4.
[0069] By braiding the open notch 10a during a complete round-trip movement of the molding tool 4 by the radial braiding machine 1, the two layers of fibers 9a, shown in Figure 2, are seated with a fiber angle of ± 80 ° with respect to the axial direction on the molding tool 4. These overlap with the wedge-shaped notch 10a and touch only partially on its bottom 4a, but not on the flanks 4a, whereas in the region of the remaining rim base they touch with positive union on the shaping tool 5. Since the two layers of fibers 9a seated consist of endless fibers, the fiber layers have two points of inversion, one at the right rim end of the air base and one inside the rectangular notch 10a, at the points of inversion at the rim ends the layers of fibers 9a are joined together.
[0070] In Figure 3, the width of the notch 10a has been reduced to width b by axial displacement of the mold parts 6, 7 along the direction of displacement 5. Thus, the layers of fibers 9a form deformed forming flanges superimposed on each other. wedge shape. By a positive union of the mold parts 6, 7 in the lower region, the width b of the reduced notch is determined and, thus, the degree of compaction or the subsequent fiber-to-matrix ratio of the fiber layers 9a. These now also touch the notch in positive union on the flanks 4a and bottom 4b and reproduce the notch or flange close to the final contour.
[0071] As shown in Figure 4, the molding tool is again overwoven with the projection reduced to width b and the fiber layers 9a seated there as well as deformed. By means of a new complete round-trip movement of the braiding core 4 along the axis of rotation symmetry 11 by the radial braiding machine, the fiber layers 9b forming the base of the ring are laid with a fiber angle of ± 80 ° with respect to in the axial direction with positive union on the molding tool 5. These fiber layers 9b then overlap the deformed fiber layers 9a and thus provide high stability of the wheel rim.
[0072] Then, in the region of the wheel rim, an external metallic tool is used, in several parts, for compression with infiltration and consolidation. This results in the wheel rim according to the invention, shown in Figure 5 in perspective and in Figure 6 in section, with a highly integrated flange. A detailed representation of the course of the fiber layers on the flange can be seen in Figure 7. Figure 7 then shows the course of endless fibers, which enter and exit again without interruption of fiber in the flange and present a reversal point at the lower end of the flange. These endless fibers can be laid, preferably in a braiding or wrapping process on the shaping tool. Figure 7b shows the course of fibers, which enter the flange without interruption of fiber. These layers of fibers are preferably formed by separately laying textile inserts on the mold parts of the molding tool as well as their insertion in the groove and deformation by displacement of the mold parts. Execution example 2
[0073] The laying of the flange fiber layers 9a takes place in a molding tool shown in Figure 8, consisting of two mold parts 6, 7, with fixed width V-shaped notch 10b, the fibers of the layers fibers 9a completely touch the inner contour of the same. As shown in Figure 9, after the positive bonding of the fiber layers 9a on the molding tool 4 V-shaped inserts 12 are integrated into the protrusions of the fiber layers 9a directed inward, corresponding to the contour of the notch 10b. Thereby, they are advantageously compressed still on the surface of the groove 10c of the molding tool 4. The surface of the insert 12 also advantageously ends with the surface of the fiber layers 9a in the region of the base of the rim. Then, the fiber layers 9b form the base of the ring on the fiber layers 9a as well as the inserts 12 embedded in them.
[0074] As shown in Figure 10, additionally, it is possible to lay layers 9a forming a flange and rim base as well as layers 9b formed an air base with inversion points in the region of the rim base, especially in the region near the rim. flange. This results in more frequent braiding of the flange region or the laying of additional layers of braiding compared to the remaining frame base. Advantageously, an additional reinforcement of the flange region is obtained. The layers not extended throughout the base of the rim in radial alignment can either be deformed to form a flange (9a) or, after inserting the insert 12, be seated on it and on the layers forming the flange (9b).
[0075] Then, the mold parts 6, 7 are axially displaced from each other and the preform is removed. The consolidation of the preform takes place in an external metallic tool, in several parts, and the inserts 12 consisting of foam serve to compress the flange region with infiltration and consolidation, and then remain in the component. Execution example 3
[0076] The molding tool 4 in several parts, reproduced in Figure 11, consists of two mold parts 6,7, which are axially displaceable with each other along the direction of displacement 5 and form a rectangular notch with straight flanks and the width a = 50 mm. In this notch, V-shaped circle segments 10c are integrated, the outer contour of which slopes with positive union on the flanks 4a of the notch and whose bottom 4b determines the internal contour of the notch. By laying braided threads 3 on the shaping tool 4 by braiding technique, the fiber layers 9a forming a flange are laid with positive union on the bottom 4b of the V-shaped circle segments 10c. The fiber layers overlap in wedge-shaped to the region of the notch and thus completely touch the bottom 4b of the circle segments 10c. By the positive bonding of the fiber layers 9a also in the groove region, the thread tension and the thread angle of the braided threads 3 can be more precisely controlled.
[0077] After the first two layers of braid have been applied, as shown in Figure 12, the mold parts 6, 7 are opened to width b> 50 mm, so that the circle segments 10c are individually displaced radially inside and can thus be removed. This makes it possible, as shown in Figure 13, to close the mold parts by reducing the width of the notch to the width c = 10 mm. This results in the deformation of the protuberances of the fiber layers 9a forming a flange. By deformation, the fiber layers 9a in the region of the notch are compressed by positive joining to the flanks 4a and to the bottom 4b of the notch formed by the mold parts 6,7 and, thus, molded to the flange close to the extreme contour. By the controlled laying of the fiber layers 9a on the surface of the circle segments 10c, the fiber layers 9a are well arranged in the flange region also after deformation.
[0078] Then there is a new over-braiding of the molding tool and fiber layers 9a with the fiber layers 9b forming the base of the ring. For the compression with infiltration and consolidation, an external metallic tool, in several parts, is used in the base of the rim. Execution example 4
[0079] The molding tool 4 shown in Figure 14 has a rectangular notch with width a with straight flanks between the two mold parts 6, 7. In this notch are rectangular circle segments 10d, which are fixed radially by one part slide 6a. The rectangular circle segments are then formed in such a way that their surface ends precisely with the surface of the remaining air base. As the molding tool 4 is plaited with a radial plaiting machine 1, the fiber layers 9a, as shown in Figure 15, are fitted with positive bonding throughout the region of the base of the rim.
[0080] By the axial movement of the sliding part 6a, the locking of the circle segments 10c is released and these can be removed from the notch without axial displacement of the mold parts 6, 7 (see arrow). With the aid of punching segments 13, the fiber layers 9a are pressed into the now open notch (Figure 16). Then or simultaneously, the mold parts 6, 7 are axially displaced and, thus, the width of the notch is reduced to width b as well as the fiber layers 9a are deformed. The sliding part 6a fixed on the outside of the mold part 6 then simultaneously defines the distance between the two mold parts 6, 7, necessary for the formation of the flange (Figure 17). After the punching segments 13 have been removed, the shaping tool 5 is again overwoven with the fiber layers 9a seated on it (Figure 18). As shown in Figure 19, in addition to laying by braiding technique of fiber layers forming the base of the ring, the laying of textile fragments 17 occurs in the region of the deformed protuberances. These reduce, in addition to the layers forming the base of the rim, the notch effect produced by the flange. For the compression with infiltration and consolidation, an external metallic tool, in several parts, is used in the base of the rim. REFERENCE LIST 1 radial plaiting machine 2 plaiting wire 3 plaiting wire 4 shaping tool 4 notch sides 4b bottom notch direction of mold part part mold part 1 sliding part mold part 2 fiber braiding fiber layers 1 and 2 forming flange and rim base fiber layers 3 and 4 forming rim base rectangular notch V-shaped notch V-shaped circle segments rectangular circle segments rotation symmetry axis foam circle segments puncture segments flange base rim points rim textile thread
权利要求:
Claims (22)
[0001]
1. Rim base made of fiber material with a flange (14) located on the inner side of the rim base (15) for fixing a wheel center or a wheel disc, characterized by the fact that the flange ( 14) is formed by protrusions, directed inward, of layers of braided or rolled fibers from the base of the ring (15), with layers of braided or rolled fibers entering the base of the ring (15) into the flange (14) without interruption and the flange flange (14) is shaped as an ideally shaped counterpart for mounting elements located on the wheel disc or wheel rim.
[0002]
2. Rim base of fiber composite material according to claim 1, characterized by the fact that the fiber layers enter and exit the flange (14) again without interruption of the rim base (15) and the lower end of the flange (14) is formed by an inversion point of the fiber layers.
[0003]
Rim base made of fiber material according to claim 1 or 2, characterized in that the layers of fibers pass through the entire base of the rim (15) as well as the entire flange (14) without interruption.
[0004]
4.Rope base made of fiber material according to any one of the preceding claims, characterized in that part of the fiber layers (9b) only partially cross the base of the rim (15).
[0005]
5.Rope base made of fiber material according to any one of the preceding claims, characterized in that the fiber layers (9b) are formed of endless braided fibers.
[0006]
6.Rope base made of fiber material according to any one of the preceding claims, characterized in that a layer of fiber layer, located radially internally, from the base of the ring, consisting of at least one layer of fibers forming a flange , presents fibers entering the flange.
[0007]
A frame base made of fiber material according to any one of the preceding claims, characterized in that a layer of fibers layer (9b), located radially externally, from the base of the frame, consisting of at least one layer of fibers forming the base of the ring, and / or textile fragments (17) additionally applied in the region of the protuberances, there are no fibers entering the flange.
[0008]
8.Rope base made of fiber material according to any one of the preceding claims, characterized by the fact that it has at least two layers, which are superimposed in a radial direction of the base of the rim, being that the fibers of the fiber layers forming the flange have a fiber angle of ± 3 ° to ± 87 °, preferably ± 15 ° to ± 65 ° and more preferably from ± 20 to ± 60 ° with respect to the axial direction of the rim base and the layer fibers of fibers forming the base of the rim have a fiber angle of ± 3 ° to ± 87 °, preferably ± 20 ° to ± 75 ° and even more preferably ± 30 ° to ± 70 ° with respect to the axial direction of the base of the rim.
[0009]
9.Rope base made of fiber material according to any one of the preceding claims, characterized in that it consists wholly or partly of textile semifinished products with fiber orientations of ± 0 to ± 90 °, preferably ± 3 to ± 87 °.
[0010]
10. Rim base made of fiber material according to any of the preceding claims, characterized by the fact that the flange (14) is continuous or in the form of distinct circle segments on the inner side of the rim base.
[0011]
11.Rope base made of fiber material according to any one of the preceding claims, characterized in that the flange (14) has inserts in the form of an interrupted circle ring or distinct circle segments (12) in the protuberances of the flange fiber layers.
[0012]
12.Rope base made of fiber material according to any one of the preceding claims, characterized by the fact that the flange (14) has a rectangular cross-section geometry with straight flanks or a U or V-shaped geometry with inclined flanks, as well as sharp or rounded edges.
[0013]
13. Process for producing a rim base, as defined in claim 1, characterized by the fact that - the laying of the fiber material is carried out by a braiding or wrapping process on a molding tool (4) corresponding to the contour of the the base of the rim (15) occurs with a continuous or segmented radial groove, -the seating takes place in such a way that the fibers of the fiber material of at least one layer of fibers enter the groove,-thus forming a preform with at least one layer of fibers with protrusions directed into the groove, - and that preform is then consolidated with a matrix material.
[0014]
14. Process according to claim 13, characterized by the fact that -the laying of the fiber material takes place in a molding tool (4) of several parts, the groove being formed by a notch limited in axial direction and radial between the different mold parts.
[0015]
15. Process according to claim 13 or 14, characterized in that, - the groove width is adjustable by axial displacement of the mold parts (6, 7) with each other.
[0016]
16. Process according to any one of claims 13 to 15, characterized in that - the protrusion, directed inwards, of at least one layer of fibers overlaps wedge-shaped over the groove, - on which it slopes only partially. internal contour of the same and by axial displacement of the mold parts (6,7) the width of the groove is reduced and the protrusion is deformed.
[0017]
17. Process according to any one of claims 13 to 16, characterized by the fact that - the protrusion, directed inwards, of at least one layer of fibers overlaps the groove, in which the internal contour thereof, tapering radially to inside, it slopes completely, and inserts (12) adapted to the internal contour, in the form of an interrupted circle ring or individual circle segments, are embedded in the protuberances of the flange fiber layers (14).
[0018]
Process according to any one of claims 13 to 17, characterized in that - the laying of fiber material occurs in a molding tool in several parts, the groove being formed by a notch, limited in axial and radial direction, between the different mold parts (6, 7), as well as the contour by circle segments located in that notch and the width, height and shape of the groove are adjustable by axial displacement of the mold parts (6 , 7) with each other as well as by the radial displacement of the circle segments (10c, d).
[0019]
19. Process according to any one of claims 13 to 18, characterized in that - the protrusion, directed inward, of at least one layer of fibers overlaps a groove, in which the internal contour completely slopes, that tapers radially inward of the circle segments (10c), and by axial displacement of the mold parts (6, 7) and by radial displacement of the circle segments (10c) the groove width is reduced and the protrusion is deformed .
[0020]
20. Process according to any one of claims 13 to 19, characterized in that inserts (12) can be integrated in the flange region (14).
[0021]
21. Process according to any one of claims 13 to 20, characterized in that -after the deformation of the protrusions (12) and / or -after the insertion of inserts (12) in the protrusion -are seated on the molding tool (4) one or more layers of fibers, which have no protrusions directed inwards.
[0022]
22. The process according to claim 15 or 18, characterized by the fact that the layers of fibers forming the flange are deformed in an approximately radial direction in the region of the flange and in the region of the protuberance.
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同族专利:
公开号 | 公开日
CN107009814A|2017-08-04|
WO2013083502A1|2013-06-13|
CN107009814B|2019-08-02|
CN103974818B|2017-08-08|
US20140333122A1|2014-11-13|
US9539855B2|2017-01-10|
US9586366B2|2017-03-07|
DE102011087921A1|2013-06-13|
US20160332391A1|2016-11-17|
TR201903317T4|2019-03-21|
EP2788175B1|2019-01-23|
CN103974818A|2014-08-06|
ES2715076T3|2019-05-31|
BR112014013054A2|2017-06-13|
EP2788175A1|2014-10-15|
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法律状态:
2018-03-27| B06F| Objections, documents and/or translations needed after an examination request according [chapter 6.6 patent gazette]|
2019-10-15| B06U| Preliminary requirement: requests with searches performed by other patent offices: procedure suspended [chapter 6.21 patent gazette]|
2020-06-16| B09A| Decision: intention to grant [chapter 9.1 patent gazette]|
2020-09-01| B16A| Patent or certificate of addition of invention granted [chapter 16.1 patent gazette]|Free format text: PRAZO DE VALIDADE: 20 (VINTE) ANOS CONTADOS A PARTIR DE 03/12/2012, OBSERVADAS AS CONDICOES LEGAIS. |
优先权:
申请号 | 申请日 | 专利标题
DE102011087921.8|2011-12-07|
DE102011087921A|DE102011087921A1|2011-12-07|2011-12-07|Rimbed with integrated flange made of fiber composite materials and a method for its production|
PCT/EP2012/074187|WO2013083502A1|2011-12-07|2012-12-03|Fiber composite rim base comprising an integrated flange, and method for the production thereof|
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