Manufacture of electric bicycle parts, electric bicycles, bicycle frames and other bicycle parts

Abstract

The present invention relates to electric bicycles and components thereof. The bicycle frame (100) of an electric bicycle is formed as a single unit and manufactured by injection molding of a reinforced thermoplastic material. The single unit includes a head tube (110), a seat tube (130) preferably having a seat post receiving portion configured to receive a seat post, a midsection connecting the head tube and the seat tube, and a rear section configured to engage a rear wheel. An elongated cavity (125) is formed in either the midsection or the rear section and configured to accommodate at least one energy storage device. The present invention also relates to electric bicycles and manufacturing methods and structures for major components such as the bicycle frame, seat post, and fork. Furthermore, methods for ensuring inter-engagement of interrelated components such as the seat post and seat tube are described.

Description

[Technical Field]

[0001] The present disclosure relates to the field of electric bicycles, and more particularly to electric bicycle components such as bicycle frames made by injection molding of reinforced thermoplastic material. Additionally, methods for manufacturing electric bicycle components such as saddle posts, electric bicycles, and bicycle frames are provided. The frame includes a head tube, a seat tube, a midsection, and a rear section, and the seat tube is configured to receive the saddle post. [Background technology]

[0002] Considering the growing population of cities, there is a need to optimize mobility and logistics systems within urban areas. Furthermore, from an environmental perspective, there is a need to reduce carbon dioxide emissions and develop transportation solutions that are more sustainable. This objective can be met by electric vehicles that do not produce exhaust gases and can replace automobiles with internal combustion engines. Considering the increasing demand for space in cities and connecting roads, the development of small electric vehicles, such as bicycles based on pedal-based propulsion systems, is desirable. Therefore, it is an object of the present invention to provide an electric bicycle that has the advantages of being an environmentally friendly, quiet, and reliable vehicle for transportation.

[0003] Electric bicycles can be operated by pedaling using muscle power, with or without assistance. In the context of the following disclosure, electric bicycles include so-called pedelecs (pedal electric bicycles), E-bikes, S-pedelecs, S-bikes or electrovelos, each of which may be configured for use as a cargo bike. That is, the term electric bicycle used throughout the following description encompasses the provision of pedaling assistance, preferably where the electric motor can be turned on manually or automatically when the pedals are operated.

[0004] When an electric bicycle is used as a pedelec (which is classified as a bicycle in Germany), the use of the electric motor may be limited so that the motor only assists while the vehicle's speed does not exceed 25 km / h. For said pedelecs, EU guidelines limit the average motor power to 250 W. A speed-limited e-bike or pedelec allows movement without significant effort. Furthermore, S-bikes or S-pedelecs are known, with higher motor power and assistance up to 45 km / h.

[0005] The present invention relates to electric bicycles, particularly to key components such as frames and saddle posts, and their manufacture. The frame, in particular, plays a key role in building a high-quality, durable bicycle. Because it serves as the skeleton of the bicycle and supports the overall structure, it is important that the material used for the frame be able to withstand the large forces applied to the bicycle. At the same time, the frame must be as lightweight as possible. Electric bicycles differ from regular bicycles in that they include additional loads, such as an electric motor and a battery or accumulator. Typically, the latter are mounted externally to the bicycle frame or inserted into a two-part metal frame. Furthermore, when an electric bicycle is configured to carry a load, even greater rigidity and stability are required.

[0006] The frame is the most important part of a bicycle. Typically, a bicycle frame structure is composed of two triangles, a main triangle and a mating rear triangle, forming a diamond frame. This diamond structure is typically composed of many individual tubular sections, which require complex joining techniques, such as welding or other joining methods. Traditional materials for bicycle frames include steel or light alloys, such as high-strength titanium or aluminum alloys. However, frames made of metals, such as aluminum alloys, usually require welding, which can lead to problems with fatigue and stress corrosion cracking at the welds, especially under harsh operating conditions, such as on cargo bikes.

[0007] Desirable characteristics of a frame include: High impact resistance and high fatigue strength, the frame being a platform for the entire e-bike and for the electrical components, for example by providing receptacles for the rear wheel, saddle post, forks, etc.; Complex shapes are required, but with excellent uniformity (e.g., receptors or holes, variations in wall thickness, and since the frame is one of the most important parts of the bicycle, uneven or defective parts are not acceptable). providing a stable seat tube for receiving and interconnecting a saddle post so that an operator can maintain a safe positioning on the electric bicycle; Possibility of mass production.

[0008] Therefore, there is a need to provide affordable technical solutions for the main components of an electric bicycle, particularly the frame and / or saddle post, that are cost-effective and capable of mass-producing, e.g., more than 200, despite the complexity of each component. At the same time, each component must fulfill the technical objective of being sufficiently rigid and stable for use as an electric bicycle. Preferably, the electric bicycle frame provides users with flexibility regarding the frame's use, such as configuring it as a cargo bike. Therefore, the frame should be designed to be sufficiently sturdy and can be provided with permanent or non-permanent components to allow for the carrying of cargo. Summary of the Invention [Problem to be solved by the invention]

[0009] The object of the present invention is to address the technical problems associated with the aforementioned objects in the prior art and to provide an electric bicycle, particularly a frame with excellent mechanical properties, while at the same time providing a lightweight product. Another object of the present invention is to provide a saddle post that can be inserted into the frame.

[0010] A further object is to address the problem of high loads introducing forces into the material of the frame and to provide a safe and stable connection between the frame and other components such as a battery or accumulator.The object is therefore a frame that is particularly suitable for receiving a wheel, with the motor being able to be located in the hub of the wheel.

[0011] Finally, not only should electric bicycles be improved by reducing the number of components required for the frame, but the frame should also be as light as possible. It should provide a complex structure for reinforcement, but also ensure the possibility of mass production of the wheels. These characteristics are advantageous for reducing costs and for manufacturing electric fleet bikes. The frame and other components of electric bicycles should also have a long lifespan and be easy to maintain.

[0012] A further objective is to enclose all electrical operating components as much as possible, thereby protecting them from both weather and potential damage, and to provide a modern platform for connections.

[0013] Another object is to provide a saddle post that is made substantially of a material other than metal and that can be securely coupled when received in the seat tube of a frame made substantially of a thermoplastic material, said frame also being adapted to receive a fork. [Means for solving the problem]

[0014] The above objectives are achieved by the bicycle frame, saddle post, electric bicycle and method of manufacturing the same according to the present disclosure.

[0015] According to a first aspect of the present invention, a bicycle frame for an electric bicycle is formed in a single piece, i.e., the frame is manufactured by injection molding of a reinforced thermoplastic material, and the single piece includes a head tube, a seat tube, a middle section, and a rear section, the middle section connecting the head tube and the seat tube, and the rear section configured to engage with a rear wheel. Furthermore, a bottom bracket is formed in the middle section.

[0016] The frame may further include an elongated cavity formed in either the central portion or the rear portion and configured to accommodate at least one energy storage unit for power and / or electrical equipment. A preferred energy storage unit includes at least one battery.

[0017] According to a preferred embodiment, the seat tube has a seat post receiving portion configured to receive a seat post.

[0018] Integrally or integrally manufactured structures avoid joining techniques that can cause undesirable stress concentrations at the joints. For example, problems such as deterioration, deformation, or fatigue caused by welding, soldering, or riveting the tube joints of a conventional bicycle frame made of multiple tubes of steel or other metals can be overcome by using a single-piece lightweight thermoplastic material. Using reinforced plastic materials can reduce the number of parts to a single piece, avoiding multiple assembly steps.

[0019] The production of frames by injection molding is made possible by providing a large mold tool that can produce the entire frame, including the head tube, seat tube, and mid-section and rear section, in a single operation step. On the one hand, the production of such a large mold tool is more complex and time-consuming than the development of a small mold tool. On the other hand, once a large mold tool is developed, it becomes possible to produce a large number of frames, thus reducing the overall manufacturing cost. Therefore, there is an advantage in that automated mass production can be realized.

[0020] Considering that frames need to be strong, stiff, and lightweight, the advantage of thermoplastic materials is that they are highly impact resistant due to the flexibility of their long polymer chains, while at the same time being lightweight. Compared to unreinforced thermoplastic materials, this reinforcement improvement makes them particularly suitable for use in frames subjected to high static loads, such as those that occur when the frame is used as a cargo bike. A further advantage of this material is that, in contrast to Duroplast, the structure of thermoplastic materials allows the melting and solidification processes to be reversed, allowing the frame to be recycled if necessary, thus providing a sustainable bicycle component.

[0021] According to a preferred embodiment of the bicycle frame, a cavity is disposed in an intermediate portion between the bottom bracket and the head tube, the energy storage portion includes at least one battery, and the cavity is configured such that the outermost periphery of the battery around the central longitudinal axis of the battery is completely surrounded by the intermediate portion.

[0022] Thus, a multi-cavity frame including tubes or semi-open cavities for one or more energy storage units is provided, manufactured by related techniques using corresponding complex injection molding tools and sliders. The cavities housing the energy storage units are preferably accessible from the top of the middle section, with at least one electrical conductor and / or at least one control line located at the bottom of the cavities. In this way, battery insertion is gravity-assisted, and at least one electrical connector at the bottom can be easily electrically connected to the battery. In this way, the energy storage units of the electric bicycle are immediately ready for use and can be easily replaced for recharging.

[0023] According to a preferred embodiment of the bicycle frame, at least one of the mid-section and the rear section is provided with a plurality of reinforcing ribs, said rear section being further adapted to support a luggage rack.

[0024] Compared to unsegmented monolithic frames, the use of multiple reinforcing ribs is an excellent way to reduce weight without sacrificing stiffness. Weight reduction can significantly contribute to the performance of electric vehicles and provide a path to reducing the vehicle's carbon dioxide emissions. The ribs preferably have a uniform wall thickness, which is both mechanically and aesthetically desirable.

[0025] For example, the ribs of the intermediate section preferably extend parallel and / or substantially perpendicular to the longitudinal axis of the intermediate section between the head tube and the bottom bracket section, at least in the region of the intermediate section. For example, part or all of the outer surface of the energy storage cavity may be free of ribs. In this way, the reinforcing ribs form a substantially square aperture.

[0026] In areas of high mechanical loads, such as the upper region of the bottom bracket, the ribs may alternatively be spaced closer together to provide increased strength and / or have generally triangular apertures. At the rear, the ribs may also extend radially outward from the center of the rear wheel hub and / or be spaced around the center of the rear wheel hub. It will be appreciated that the ribs may be formed in any other suitable pattern, so long as they provide increased mechanical load capacity while simultaneously providing dimensional stability and weight reduction.

[0027] According to a preferred embodiment, the material of the bicycle frame is a thermoplastic material and comprises at least one reinforcing component selected from the group of carbon fibers, glass fibers, natural fibers, carbon nanotubes, or combinations thereof, and the frame may optionally comprise areas with a higher weight ratio of fibers to thermoplastic material in order to support higher mechanical loads.

[0028] The combination of thermoplastic materials and reinforcing elements provides a good balance of high stiffness, high toughness, and light weight. Therefore, this material is suitable for use in bicycle frames that must withstand large forces and loads. The high impact resistance of thermoplastic materials with one or more reinforcing elements can increase the durability of bicycles, especially when used on cargo bikes.

[0029] According to a preferred embodiment of the bicycle frame, the glass fiber content of the reinforced thermoplastic material is between 20 and 65% by weight, preferably 50% by weight, more preferably 30% by weight, said thermoplastic material being selected from polyamide 6 (PA6), polyamide 6.6 (PA6.6) or mixtures thereof, at least in the areas of high mechanical loads.

[0030] That is, a preferred polymeric material for use as the carrier resin is polyamide, which is typically present in an amount of about 35 to about 80 weight percent. That is, the weight ratio of polyamide to glass fiber in the polymeric material ranges from about 80:20 to about 35:65. More typically, the amount of polyamide ranges from about 45 to about 70 weight percent, preferably 50 weight percent, and even more typically about 70 weight percent, based on the total weight of the polymeric matrix including both the polyamide and the reinforcing component.

[0031] Bicycle frames made of thermoplastic material and containing at least 30% by weight of glass fibers as reinforcing components, relative to the total weight of the polymer matrix, meet the stability and safety requirements according to the German and European standards set out in standards EN 15194 (European Standard "Cycles - electrically powered assisted cycles - EPAC Bicycles", published in November 2018) and DIN 79010 (title: "Cycles - Transportation bikes and cargo bikes - Requirements and test methods for single- and multi-track cycles", published in February 2020). Furthermore, bicycle frames according to the invention meet the standards of the International Organization for Standardization (ISO), such as ISO 4210 according to national standards, such as DIN EN 4210 for Germany or SN EN 4210 for Switzerland. For example, the dynamic test according to DIN 79010:2020-02-5.9 or the test according to DIN EN 15194:2018-11-4.3.7.2 is met by the bicycle frame of the invention.

[0032] In yet another embodiment, the thermoplastic material may include a colorant component in addition to the reinforcing components. The colorant component may be a dye, a combination of pigments, a combination of dyes, or a combination of at least one pigment and one or more dyes. The choice of colorant depends on the final color desired by the designer of the thermoplastic frame, who may use colors to improve visibility and, therefore, traffic safety. It will be understood that other suitable impact modifiers, such as UV stabilizers known in the art, may also be used.

[0033] In terms of UV resistance, bicycle frames made from reinforced thermoplastic materials without added UV stabilizers can withstand 240 hours of prolonged sunlight exposure and 1000+ / -W / m². 2 It should be noted that the device already meets the requirements of the standard DIN 75220 D-OUT-T test, which reproduces radiation of

[0034] According to a preferred embodiment, at least one metal insert and / or at least one plastic insert made of a plastic that is stiffer than the thermoplastic material of the bicycle frame is connected to the thermoplastic material of the bicycle frame by injection molding, the metal insert or plastic insert preferably being located in or near one or more of the following components: head tube, seat tube, bottom bracket, rear wheel bearing, brake caliper and luggage rack.

[0035] Preferably, for example, a luggage rack can be attached and removed as needed using metal and / or plastic inserts at the rear of the frame, thus providing support for mounting other components such as luggage racks or mudguards or other protective plates, driver or passenger seat backs, etc., while maintaining the integrity and overall appearance of the frame.

[0036] According to another preferred embodiment, the plastic insert for the rear wheel support element includes an aperture for injection molding and a form-fit connection. The latter form-fit connection is particularly suitable for receiving, for example, a brake element. Thus, a preferred embodiment of the injection molding and form-fit connection is designed to receive a brake element or other component that is subject to very high loads during operation. The use of such a form-fit connection increases the stability and safety of the respective connection.

[0037] In a preferred embodiment of a bicycle frame configured for 24-inch wheels, the weight of the bicycle frame without inserts is less than 10 kg, preferably less than 8.5 kg, and even more preferably in the range of approximately 5 kg to 6 kg. The frame can also be configured for other wheel dimensions ranging from 16 inches to 29 inches. It should be noted that reducing the wheel size requires reducing the bicycle frame dimensions, such as the frame height H2, which can be defined as the height between the center of the bottom bracket and the highest center point of the seat post. For frames configured for wheels 24 inches or smaller (e.g., 20 inches or 18 inches), the minimum frame weight can be 2 kg.

[0038] According to a preferred embodiment, the bicycle frame further includes a pin assembly on the seat tube having at least one movable pin configured to engage a corresponding recess in the seat post, the pin assembly being configured to lock the seat post at a predetermined height relative to the seat tube, thereby allowing a predetermined saddle height to be selected.

[0039] Such a locking pin assembly, preferably a quick-release locking assembly, provides a means for positioning and subsequently securely connecting the seat post to the seat tube at a desired height. At least one movable pin allows for easy and reliable aligned interengagement of the seat post and seat tube. In this manner, saddle height can be easily adjusted to suit the needs of various users.

[0040] According to a preferred embodiment, the rear of the bicycle frame comprises a rear wheel hub support and at least one luggage rack.

[0041] According to another preferred embodiment, the rear of the bicycle frame includes a recess for accommodating a pivotable locking lever configured to move at least one pin of the pin assembly through a corresponding opening in the seat tube.

[0042] According to a preferred embodiment, the pin assembly is a quick-release locking assembly comprising a cam plate and a pin assembly made of a reinforced thermoplastic material, the lever being movable from a release position to a locking position and configured to be coupled via the cam plate to a pivotable pin assembly including at least one pin, the cam plate defining an elongated guide rail or aperture, the pin assembly picker being movably coupled to the cam plate and moving within and constrained by the guide rail or aperture from the release position to the locking position, the pin assembly preferably being spring-biased toward the locking position by a spring element to securely secure the quick-release locking assembly in the locking position.

[0043] According to a preferred embodiment, the seat tube has an at least partially non-circular inner cross section such that rotation of the corresponding seat post about the seat post axis is limited or prevented.

[0044] According to a preferred embodiment, the axially movable seat post is guided into a sliding insert located in the upper part of the seat tube between the inner diameter of the seat tube and the outer diameter of the seat post, and all adjacent parts such as the seat tube, the sliding insert and the seat post are made of thermoplastic material.

[0045] The use of a sliding insert can reduce play between adjacent components, thereby improving the alignment and sliding action of the seat post within the seat tube. Furthermore, the sliding insert ensures greater precision when the operator positions the seat post at a desired height. Furthermore, the sliding insert results in increased stability of the seat post. A quick-release locking assembly allows the seat post and saddle to be quickly and specifically adjusted to the preferred seat height of the cyclist for whom the bicycle is intended.

[0046] According to a preferred embodiment, the head tube further comprises at least one bearing bush and is adapted to receive a corresponding steering tube of a front fork made of metal and / or thermoplastic material.

[0047] The at least one bearing bushing is sized so that the front fork assembly is easily journalled within the head tube with minimal play.

[0048] According to a preferred embodiment, the electric equipment of the electric bicycle includes at least one of a cable guided at least partially within the bicycle frame, an electric drive unit including an electric motor (optionally a chainless drive system), an energy storage management system, a brake control system, a central control unit, at least one processor, at least one memory (optionally including one or more applets), at least one user interface, a communication interface for a diagnostic tool and / or the Internet, a plurality of lights, an automatic lock, and a plurality of indicators.

[0049] The electrical devices can be used to deploy applications or applets, such as Internet of Things applications. The latter IoT applications are highly customizable, allowing, for example, predictive maintenance. Such applications can be operated using a user interface, such as a human-machine interface (HMI). The use of at least one control unit, one or more processors, and sensors, optionally in combination with memory and / or applets, can be advantageous in controlling and monitoring components of the electric bicycle, such as the electric motor, drive system, or energy storage, as well as other electrical components, such as lights, automatic locks, and indicators. The user interface or communication interface can, for example, display the results of diagnostic tools.

[0050] According to another aspect of the present invention, there is provided a seat post manufactured by injection molding of a reinforced thermoplastic material, formed of a single piece of construction and configured to be received in a seat tube of a bicycle frame manufactured by injection molding of a reinforced thermoplastic material, the seat post including a hollow profile with a plurality of protruding ribs for interengaging with at least one pin of a locking assembly disposed on the seat tube.

[0051] The seat post is designed to be lightweight, weighing less than 0.5 kg, preferably 470 g or less. Typical seat posts with lengths up to 400 mm range in weight from 0.25 to 0.5 kg. The seat post of the present invention has been tested for safety and stability in accordance with the standards DIN EN 15194 and DIN 79010, such as DIN 79010:2020-02-5.17 or DIN EN 15194:2018-11-4.3.15.3.

[0052] In the context of the present invention, the seat tube and seat post of the bicycle frame may be coupled by a locking assembly that complements each other directly or indirectly via a sliding insert, and is preferably a quick-release locking assembly that uses a spring element to bias the locking assembly towards a locked position, so that the seat post and at least one subsystem of the bicycle frame form interrelated members.

[0053] According to a preferred embodiment, the seat post comprises a hollow profile having a U-shaped cross section, the hollow profile being provided with transverse ribs dividing the hollow profile into a plurality of segments, the protruding ribs being configured to interengage with at least one pin or pins of the locking assembly, the ribs being arranged transversely to the longitudinal axis of the seat post and may be arranged on the outward facing side of the free end of the hollow profile.

[0054] According to a preferred embodiment, the seat post is further guideable within a sliding insert fixed to the upper part of the seat tube via an interengaging element, and the seat post further comprises a flange at the free end of the seat post that is configured to abut against the lower edge of the sliding insert to prevent complete withdrawal from the seat post.

[0055] According to another aspect of the present invention, there is provided a method for manufacturing a bicycle frame having a one-piece structure, the method comprising the steps of: injection molding a reinforced thermoplastic material to integrally form a one-piece structure including a head tube, a seat tube, a mid-section, and a rear section, wherein a single injection tool is used to form a bottom bracket in the mid-section, and applying and withdrawing a plurality of sliders to the injection tool at the head tube, seat tube, mid-section, and rear section to form an elongated cavity configured to accommodate the head tube, the seat tube, and a battery.

[0056] The use of sliders, preferably with folding cores, allows for mass production of off-tool bicycle frames with excellent precision. In this way, a manufacturing method is provided that can provide off-tool bicycle frames. That is, the product can be produced without additional finishing steps such as grinding or spraying. The manufacturing process is fully automated and cost-effective. Colored, particularly UV-resistant, particularly reinforced areas, or other improved areas of the bicycle frame can be produced by adding colorants and / or reinforcing components to the thermoplastic material prior to the injection molding process.

[0057] According to a preferred embodiment, the method further comprises the step of connecting one or more inserts of metal or plastic in areas of higher mechanical load by injection molding, and optionally back-molding at least a portion of the one or more inserts through apertures for connection by press fit and / or form fit.

[0058] In this way, a single mold for the bicycle frame is provided with additional parts, which, together with the slider and preferably the self-folding core, allow for the mass production of off-tool bicycle frames with excellent precision. By integrating inserts, further functions can be integrated, for example improving the mechanical stability in areas where forces are introduced.

[0059] Furthermore, other parts of the electric bicycle, such as the seat post, slide insert, and fork, are made by injection molding. Furthermore, the wheel is also manufactured as a one-piece injection molded part.

[0060] According to another aspect, there is provided an electric bicycle having a bicycle frame according to the first aspect of the present invention, further comprising a rear wheel and a fork connected to the front wheel and the steering portion, the fork being one piece made of reinforced thermoplastic material, or the fork comprising metal and thermoplastic material, and the steering tube of the fork being made of metal.

[0061] Electric bicycles include pedelecs, which use an electric motor to assist the vehicle's propulsion. It should be noted that the electric bicycle of the present invention meets the safety and stability requirements of the EN 15194 and DIN 79010 standards. For example, after connecting the electric motor and other electrical components, an EMV (electromagnetic compatibility, also known as EMC) test showed that the electric bicycle complies with EN 15194 4.2.15.1 and 4.2.15. Further testing regarding the possibility of connecting a trailer was also conducted, and this testing followed the guidelines of DIN 15918:2017:05, making the electric bicycle particularly suitable as a cargo bike. Furthermore, the bicycle frame and seat post of the electric bicycle of the present invention also comply with the ISO 4210 standard.

[0062] The present disclosure relates to, but is not limited to, the following aspects:

[0063] 1. A bicycle frame for an electric bicycle, formed in one piece and manufactured by injection molding of reinforced thermoplastic material, The integrated structure is The head tube and a seat tube having a seat post receiving portion preferably configured to receive a seat post; an intermediate portion connecting the head tube and the seat tube; a rear portion configured to engage the rear wheels; Including, The bottom bracket is formed in the middle part, A bicycle frame having an elongated cavity formed in either a mid-portion or a rear portion and configured to house at least one energy storage unit for power and / or electrical equipment.

[0064] 2. The elongated cavity is disposed in the middle portion between the bottom bracket and the head tube, and the energy storage unit includes at least one battery; A bicycle frame as described in embodiment 1, wherein the elongated cavity is configured such that the outermost periphery of the battery around the longitudinal central axis of the battery is completely surrounded by the intermediate portion.

[0065] 3. The bicycle frame of aspect 1 or 2, wherein a plurality of reinforcing ribs are provided on at least one of the midsection and the rear section, the rear section being further configured to support a luggage rack.

[0066] 4. The bicycle frame of any of aspects 1-3, wherein the reinforced thermoplastic material includes at least one reinforcing component selected from the group consisting of carbon fiber, glass fiber, natural fiber, carbon nanotubes, or combinations thereof, and optionally, the bicycle frame includes regions with a higher weight ratio of fiber to thermoplastic material to support higher mechanical loads.

[0067] 5. The glass fiber content of the reinforced thermoplastic material is 20-65% by weight, preferably 50% by weight; 5. The bicycle frame of claim 4, wherein the thermoplastic material is selected from PA6, PA6.6, or mixtures thereof, at least in areas subjected to higher mechanical loads.

[0068] 6. At least one metal insert and / or at least one plastic insert of a plastic more rigid than the reinforced thermoplastic material of the bicycle frame is connected to the reinforced thermoplastic material of the bicycle frame by injection molding; The metal or plastic insert preferably comprises the following parts: Head tube, seat tube, bottom bracket, rear wheel bearings, brake calipers and luggage rack 6. The bicycle frame of any one of aspects 1 to 5, wherein the bicycle frame is disposed on or near one or more of the following:

[0069] 7. A bicycle frame according to aspect 6, wherein the plastic insert for the rear wheel support element is provided with an aperture for injection molding and form-fit connection, and is optionally configured to receive a brake element.

[0070] 8. A bicycle frame according to any one of aspects 1 to 7, further comprising a pin assembly on the seat tube having at least one movable pin configured to engage with a corresponding recess in the seat post to lock the seat post at a predetermined height.

[0071] 9. A bicycle frame as described in aspect 8, wherein the rear portion includes a rear wheel hub support and at least one of a luggage rack and / or a recess for accommodating at least a portion of the pin assembly and a lever configured to move at least one pin of the pin assembly through a corresponding opening in the seat tube.

[0072] 10. The pin assembly is a pivotable pin assembly that forms a quick-release locking assembly with the cam plate and is made of reinforced thermoplastic material; A bicycle frame as described in aspect 9, wherein the lever is movable from a release position to a locking position and is configured to be coupled via a cam plate to a pivotable pin assembly including at least one pin, the cam plate defining an elongated guide rail or aperture, and a picker of the pivotable pin assembly is movably coupled to the cam plate to move the pivotable pin assembly from the release position to the locking position within the guide rail or aperture while being constrained by the guide rail or aperture, and the pivotable pin assembly is preferably spring-biased toward the locking position by a spring element.

[0073] 11. The bicycle frame of any of aspects 1-10, wherein the seat tube has an at least partially non-circular inner cross-section such that rotation of the corresponding seat post about the seat post axis is limited or prevented.

[0074] 12. The bicycle frame of any of aspects 1-11, wherein the sliding insert is configured to guide an axially movable seat post into the sliding insert positioned at the top of the seat tube between the inner diameter of the seat tube and the outer diameter of the seat post.

[0075] 13. A bicycle frame according to any one of aspects 1 to 12, wherein the head tube further comprises at least one bearing bushing and is configured to receive a corresponding steerer tube of a front fork made of metal and / or thermoplastic material.

[0076] 14. The electrical equipment of the electric bicycle a cable guided at least partially within the bicycle frame; an electric drive unit including an electric motor, optionally a chainless drive system; Energy storage management systems, Brake control system, central control unit, at least one processor, Optionally, at least one memory containing one or more applets; at least one user interface; communication interface for diagnostic tools and / or the Internet, Multiple lights, Auto-lock, and Multiple Indicators 14. The bicycle frame of any one of aspects 1 to 13, comprising at least one of the following:

[0077] 15. A seat post manufactured by injection molding of reinforced thermoplastic material, formed of a unitary construction and configured to be received by a seat tube of a bicycle frame manufactured by injection molding of reinforced thermoplastic material, The seat post includes a hollow profile having a plurality of protruding ribs for interengaging with at least one pin of a locking assembly disposed on the seat tube.

[0078] 16. The hollow profile has a U-shaped cross section including transverse ribs that divide the hollow profile into segments; A seatpost as described in aspect 15, wherein the protruding rib is configured to interengage with at least one pin or multiple pins of the locking assembly, and the protruding rib is positioned laterally on an outward-facing side of the free end of the hollow profile.

[0079] 17. A seat post as described in aspect 16, wherein the seat post can be further guided within a sliding insert fixed to the upper part of the seat tube via at least one interengaging element, and the seat post further comprises a flange at the free end of the seat post configured to abut against the lower edge of the sliding insert, thereby preventing complete withdrawal from the seat post.

[0080] 18. A method of manufacturing a bicycle frame having a one-piece structure, comprising the steps of: Reinforced thermoplastic materials are injection molded using a single injection tool, Head tube, seat tube, The middle part in which the bottom bracket is formed and rear end Integral forming a unitary structure comprising: providing and withdrawing a plurality of sliders onto the head tube, the seat tube, the mid-section, and the rear injection tool to form an elongated cavity configured to house the head tube, the seat tube, and an energy storage unit, preferably including at least one battery; A method comprising:

[0081] 19. The method of embodiment 18, further comprising the step of connecting one or more inserts of metal or plastic to areas of high mechanical load by injection molding, and optionally back-molding at least a portion of the one or more inserts through an aperture for connection by press fit and / or form fit.

[0082] 20. An electric bicycle having a bicycle frame according to any one of aspects 1 to 14, and further comprising a rear wheel and a fork connected to the front wheel and steering portion, wherein the fork is an integral part made of a reinforced thermoplastic material, or the fork comprises a metal and a thermoplastic material, and the steering tube of the fork is made of metal.

[0083] The accompanying drawings depict exemplary embodiments of the present disclosure and illustrate, by way of example, the principles of the present disclosure and are not intended to be drawn to scale. The drawings are included to provide an explanation and further understanding of various aspects and embodiments, but are not intended to limit the disclosure to the embodiments shown in the drawings, and are not necessarily drawn to scale. Where a reference number follows a technical feature in a drawing or detailed description, the reference number is included solely to enhance comprehension of the drawing and description. For clarity, not every component is labeled in every drawing.

[0084] As used in this disclosure, the term "at least" means "one or more" of the preferred options. [Brief explanation of the drawings]

[0085] [Figure 1] 1 is a perspective view of a bicycle frame according to an exemplary embodiment; [Figure 2A] 10 is an exploded view of a further embodiment of a bicycle frame. [Figure 2B] FIG. 2B is a detailed side view of a bicycle frame illustrating the geometric design of the embodiment shown in FIG. 2A. [Figure 3A]FIG. 1 is a detailed perspective view of a bicycle frame, including a portion of the rear section, the seat tube, and a portion of the mid-section including a cavity for energy storage. [Figure 3B] FIG. 10 is a perspective view of another embodiment of a bicycle frame with cables on the head tube and a partially covered rear section. [Figure 4A] FIG. 1 is a bottom perspective view of a bicycle frame with mudguards, a lever with cam plate and a luggage rack integrated into the rear of the bicycle frame and a seat post inserted into the seat tube of the bicycle frame. [Figure 4B] 10 is a perspective view of another embodiment of a bicycle frame with a fork configured to be inserted into a head tube. [Figure 5A] FIG. 10 is an exploded view of an energy storage unit configured to be inserted into a cavity in the midsection located adjacent the head tube. [Figure 5B] FIG. 2 is a perspective view of a fork blade and a steerer tube of the fork. [Figure 5C] FIG. 5C is an exploded view of the fork shown in FIG. 5B. [Figure 6A] FIG. 1 shows a seat post and a saddle with a notch therein. [Figure 6B] FIG. 6B is a side view of the seat post of FIG. 6A inserted into the seat tube of a bicycle frame. [Figure 7A] FIG. 1 is a rear perspective view of the seat post. [Figure 7B] 1A and 1B are a perspective view and a diagonal top view of a seat tube. [Figure 7C] FIG. 7B is a diagram showing the cross section AA shown in FIG. 7A. [Figure 8] FIG. 10 is a perspective view of a pivotable pin assembly. [Figure 9A] FIG. 1 is a perspective view of the pin assembly in an open or released position along with a portion of the seat tube and a portion of the sliding insert. [Figure 9B] FIG. 9B is a perspective view of the pin assembly of FIG. 9A in a pivoted position. [Figure 9C]FIG. 10 is a perspective view of the pin assembly engaging the seat tube in a coupled or locked position. [Figure 10A] FIG. 1 is an enlarged perspective side view of a spring-loaded pin assembly in a recess in the rear of a bicycle frame. [Figure 10B] FIG. 10 is a perspective view of the pin assembly in combination with the cam plate interengaging with a corresponding recess in the seat tube. [Figure 10C] FIG. 1 is an enlarged perspective top view of the pin assembly, a perspective view of the top of the pin assembly and a portion of the slide insert and seat tube. [Figure 11] FIG. 1 is a side view of an electric bicycle with a luggage rack and basket. [Figure 12] FIG. 2 is a schematic diagram showing electrical components of the bicycle frame. [Figure 13] FIG. 2 is a schematic diagram of connections between bicycle components. [Figure 14] FIG. 2 is an enlarged perspective view of the center and rear portions of the electric bicycle. [Figure 15] 1 illustrates bicycle frame and fork load cases. FIG. [Figure 16] 10A-10C are diagrams showing the manufacturing of a bicycle frame using a slider. DETAILED DESCRIPTION OF THE INVENTION

[0086] FIG. 1 shows a perspective view of a bicycle frame 100 for an electric bicycle formed from a single piece of construction. Fabricated from a reinforced thermoplastic material, the single piece structure includes a head tube 110, a seat tube 130, a midsection 120, and a rear section 140. The rear section includes a plurality of reinforcing ribs, such as rib 142, for reinforcement. The rear section includes a recess 163 or receptacle with sidewalls 144 for at least a portion of a locking assembly (not shown in FIG. 1, see FIG. 10A) configured to lock the height of a seat post (not shown in FIG. 1). The midsection 120 integrates a cavity for a bottom bracket 121 and a cavity 125 for an energy storage device 150, such as a battery. The rear section includes opposing rear wheel bearings 141 for connection to the rear wheel (not shown in FIG. 1).

[0087] The exploded view shown in FIG. 2A shows the bicycle frame 100 shown in FIG. 1 and also shows parts including plastic 170 and metal inserts 171 that can be connected to the thermoplastic material of the bicycle frame 100 by injection molding.

[0088] The plurality of reinforcing ribs 102, 105, 106 are integrally molded with the bicycle frame to reduce weight without sacrificing stiffness, and the ribs have a substantially uniform wall thickness, which is mechanically and aesthetically desirable.

[0089] The ribs of the midsection include longitudinal ribs 102l that extend preferably parallel to the longitudinal axis of the midsection 120, at least in the spatial region between the head tube 110 and the bottom bracket 121. Additionally, there are transverse ribs 102t that are substantially perpendicular to the longitudinal axis of the midsection. The transverse ribs 102t, in combination with the longitudinal ribs 102l, form a lattice. In this manner, the intersecting ribs 102t and 102l form a substantially square structure that is closed at the bottom by the surfaces of the midsection 120, reinforcing the regions of the midsection 120. Part, or alternatively all (not shown), of the outer surface of the energy storage cavity 125 is free of ribs.

[0090] 2A, the peripheral region of the intermediate portion 120 above the bottom bracket 121 has ribs 102 that form a substantially triangular structure, dividing the interior region into areas of smaller dimensions than the rectangular structure for greater stability. Thus, a bicycle rider can place their feet on this stable region, which is oriented substantially horizontally in a side view of the bicycle frame 100, as shown, for example, in FIG. 2B.

[0091] As shown in Figure 2A, the bottom portion below the bottom bracket 121 includes parallel lower edges 101 integrated with an inner grid therebetween. The grid includes X-shaped strips 103x and longitudinal strips 103 parallel to the lower edge 101 of the bicycle frame 100.

[0092] From each of the lower edges 101 there is a support on which a bearing 107 for each kickstand is mounted (see, for example, reference numeral 174 in FIG. 11).

[0093] In areas with higher mechanical loads, such as the area above the bottom bracket 121, the distance between the ribs can be reduced to increase strength. The rear section 140 includes a polygonal window 159 with rounded corners. Stability of the peripheral portion of the rear section 140 is also provided by reinforcing ribs 105, 106. On the one hand, the reinforcing ribs 106 are spaced circumferentially around the center of the rear wheel hub, and on the other hand, the reinforcing ribs 105 substantially intersect these circumferential ribs 106. The circumferential ribs 106 near the rear wheel bearing 141 may be formed as radial ribs 105 extending radially from the center of the rear wheel bearing 141. It should be noted that the ribs may be formed in any suitable pattern and direction other than that shown, as long as at least a portion of the ribs is arranged to protrude not only from the inner edge of the window 159 but also from the outer edge of the rear section 140, thereby improving the mechanical load capacity and stability at the edges. The use of reinforcing ribs 105, 106, 102l, 102t, etc. provides dimensional stability without adding weight to bicycle frame 100.

[0094] 2A shows metal parts, such as metal inserts (111, 112, 122), made of, for example, aluminum or a plastic (170) that is stiffer than the thermoplastic material of the bicycle frame, that are configured to be inserted directly into the mold prior to the injection molding process. During injection molding, the reinforced thermoplastic material is molded partially or completely around the inserts. The metal inserts in the head tube 110 are preferably located in the upper part of the head tube (see metal insert 111) and the lower part of the head tube (see metal insert 112).

[0095] Generally, there may be one or more additional metal and / or plastic inserts near one or more of the following components to mechanically strengthen each area: seat tube 130, bottom bracket 121, rear wheel bearing 141, brake caliper, and luggage rack 114 (see, for example, FIG. 4A).

[0096] A combination of one or more metal inserts 171 and a plastic insert 170 is provided near each bearing 141 of the rear wheel to improve mechanical stability. The plastic insert 170 is a preform containing a reinforcing component (e.g., 30% glass fiber content by weight) and has multiple apertures, one of which is configured for mounting the rear wheel hub and at least one for a brake component. For example, a disc brake system, typically including a caliper housing, may be mounted.

[0097] Another purpose of the multiple inserts is to securely and stably fasten additional components to the bicycle. For example, inserts 122, preferably four to six metal inserts, are evenly spaced around the circular opening in bottom bracket 121 to secure the crankshaft.

[0098] Additionally, FIG. 2A shows support elements 113 at their rear 140 below luggage rack 114 that are not molded around but are configured to be screwed into corresponding threaded holes 143 in the injection mold for mounting a rear luggage rack (not shown).

[0099] FIG. 2B is a detailed side view of a bicycle frame illustrating the geometric design of the embodiment of FIG. 2A. Bicycle frame size can be characterized by various characteristic dimensions, such as the length or angle between axes. More specifically, the frame can be characterized by its frame height H2. Height H2 is the vertical distance between the center of the bottom bracket 121 and the center of the seat tube 130, and ranges from 35 cm to 55 cm, preferably from 44 cm to 48 cm. Furthermore, the seat tube 130 can be defined by its length along its longitudinal axis c. The seat tube angle β is approximately 18° between the seat tube's vertical axis y and longitudinal axis c, which corresponds to an angle of 72° between axis c and the horizontal axis x. Other preferred seat tube angles β can be preferably in the range of 16° to 24°. Furthermore, a seat tube angle β of 18° corresponds to a width W2 between the center of the bottom bracket (where the x-axis and y-axis intersect) and the top of the seat tube, measured at the center, of approximately 19 cm. The height H2 may preferably be 44.5 cm. However, if other angles are selected, other widths W2 between about 17 cm and 22 cm and other heights H2 will result.

[0100] Another characteristic angle of the bicycle frame 100 is the angle α between the longitudinal axis a of the head tube 110 and the vertical axis d passing through the center of the rear wheel aperture. In the exemplary embodiment shown, α is 22°.

[0101] 2B further shows a height H1, defined as the vertical distance between the lowest center of the head tube (the intersection of the longitudinal center axis a of the head tube with the plane formed by the circular lower edge of the head tube) and a horizontal axis x1 passing through an axis r parallel to the rear wheel axis. This height H1 is preferably about 35 cm.

[0102] Another characteristic dimension of the bicycle frame 100 is the horizontal distance W1 between the bottom center of the head tube 110 and a vertical axis d passing through the rear wheel axis r located at the center of the rear wheel aperture, which is preferably about 1 m.

[0103] It should be noted that bicycle frame 100 is preferably sized for use with the following preferred wheel nominal diameter of 24 inches. Other wheel sizes ranging from 16 to 29 inches may also be used if the bicycle frame is sized proportionately.

[0104] 2B also shows a central longitudinal axis b through the cavity 125 for the energy storage unit 150 (see, e.g., FIG. 1). The axis b forms an acute angle δ with the axis m of the intermediate portion 120. Other dimensions of the cavity 125 can be provided depending on the size of the battery used. A substantially vertical extension approximately parallel to the vertical gravity force facilitates insertion of the energy storage unit.

[0105] FIG. 3A shows details of the bicycle frame, including a portion of the seat tube 130, a portion of the midsection 120, and rear section 140 including a cam plate 146 of a locking assembly 145 made of a reinforced thermoplastic material. Cam plate 146 mates with and serves to guide a picker 149 (not shown in FIG. 3A, see FIG. 8) of a pin assembly 168 (not shown in FIG. 3A, see FIG. 8). Cam plate 146 includes a guide rail or aperture on its underside for moving picker 149 from a released position to a locked position. See FIGS. 8 and 9A-10B for details of the pin assembly.

[0106] 3B shows a close-up view of the bicycle frame, with rear portion 140 including a rear wheel hub support and at least a portion of luggage rack 114. Recess 163 and recess sidewalls 144 house pivotable locking assembly 145 configured to move at least one pin 148 of locking assembly 145 through a corresponding opening in seat tube 130.

[0107] In addition to the previous views of the bicycle frame 100, FIG. 3B shows cables 109 guided through the head tube 110. In a preferred embodiment, cables 109 for the right and left brakes, respectively, can be provided (see references 187 and 188 in FIG. 12). Reference 108 further indicates the location of the cables and their routing inside the frame in the intermediate section 120. These cables 109 can electrically connect bicycle components (see FIG. 12 or FIG. 13 for exemplary embodiments of the use of the cables). A rear partial cover 116 is used to protect the cables from dirt or water. The remaining uncovered section, where the cables are guided between the head tube 110 and the bottom bracket 121, can also be covered for protection by a cover (not shown).

[0108] 4A is a perspective view of the bicycle frame from below, showing lever 147 and cam plate 146 of locking assembly 145, which may be made, for example, of a reinforced thermoplastic material that is integrated into bicycle frame 100. Lever 147 is movable from a released position to a locked position and is connected via cam plate 146. Additionally, FIG. 4A shows luggage rack 114 attached to rear section 140.

[0109] Figure 4B shows a bicycle frame and a fork 190 with fork blades 192 and a steering tube 191. The latter can be inserted into the head tube 110 and is shown in more detail in Figures 5B and 5C.

[0110] FIG. 5A shows an exploded view of an energy storage unit 150, which is a battery (BAT), configured to be inserted into a cavity 125 in the middle section 120 of the bicycle frame and adjacent to at least a portion of the head tube 110. Thus, an elongated cavity 125 is formed in the middle section 120 and configured to house an energy storage unit 150, such as a battery BAT. A cover 155 for the energy storage cavity 125 is provided to protect the battery. The battery BAT is configured to store energy for power and electrical devices and may be a wet electrolyte lithium-ion battery or a solid-state lithium battery. The energy storage unit is not limited to a lithium solution; various combinations and materials of anodes, cathodes, and electrolytes may also be used, as long as the purpose of storing energy is met and one or more of the following advantageous characteristics are met: High volumetric electrical energy density, high power density for fast charge and discharge rates, long cycle life, ionic conductivity for ion transport between electrodes as well as electrochemical stability and scalability.

[0111] When the energy storage unit 150 is inserted, at least a portion of the battery (BAT), i.e., at least a portion of the bottom and side walls, is enclosed by the middle portion 120 for a snug fit. The longitudinal axis of the battery (BAT) forms an acute angle with the longitudinal axis m of the middle portion (see angle δ in FIG. 2B ). In this way, the energy storage unit 150, such as the battery (BAT), can be easily inserted and replaced. The top of the battery (BAT, 150) includes a plug charging connection 157. For easy access, the charging connection 157 can be combined with a respective recess or opening in the middle portion 120 so that the battery (BAT, 150) does not need to be removed from the cavity 125 during the charging process.

[0112] 5B shows a perspective view of an exemplary embodiment of a fork 190 with fork blades 192 and a steerer tube 191. Both components may be made of a thermoplastic material. The steerer tube 191 may alternatively be made of metal.

[0113] The entire fork can be manufactured by injection molding using metal inserts, such as aluminum inserts, in the areas where forces are introduced. As an alternative to injection molding, the fork 190 can also be manufactured by thermoforming. If the steerer tube 191 is made of a thermoplastic material, two ribs 196 for limiting the steering angle can be provided on opposite sides of the steerer tube 191. The steerer tube 191 is received by the head tube 110, which includes at least one metal insert (see reference numbers 111 and 112 in FIG. 2A) configured to be positioned therein. Such a metal insert 111 is configured to receive a corresponding bearing.

[0114] Additionally, a circular insert 101, preferably made of metal, is provided near the axle of the front wheel (not shown). The lowest insert 101, surrounding the circular aperture, is configured to mount the axle or hub of the front wheel 194 (not shown in FIG. 5B, see FIG. 11). Other inserts 101 are configured to mount brake components, including calipers. For increased stability, these inserts 101 may be part of a plastic insert 193, preferably formed as a preform and made of a plastic more rigid than the thermoplastic material of the fork 190. On the sides where the blades 192 face each other, the preform of the plastic insert 193 is molded around and includes a reinforcing element (e.g., preferably with a glass fiber content of 30% to 60% by weight). An aperture at the top of the fork blade 192 can be used to attach a mudguard (not shown), preferably made of a thermoplastic material, via a detent mechanism. FIGS. 5B and 5C show reinforcing ribs on the outer side of the fork blade 192. There may also be reinforcing ribs at least partially on the inside of the fork blade 192 .

[0115] Figure 5C shows an exploded view of Figure 5B, with the steerer tube 191 separate. That is, the fork blades 192 can be combined with a metal steerer tube 191 or a steerer tube 191 made from a thermoplastic material with a limited steering angle.

[0116] 6A shows a perspective view of a seat post 160. The seat post 160 includes a notch 167 extending transversely to the longitudinal axis of the seat post 160. Furthermore, a saddle 161 is attached to the seat post 160.

[0117] FIG. 6B shows a two-dimensional (2D) side view of a portion of seat tube 130 and an adjacent portion of rear section 140, with seat post 160, shown in FIG. 6A, inserted into seat tube 130. One or more holes or apertures 136 are disposed in seat tube 130 for receiving one or more interengaging elements 165 of a sliding insert. Exemplary embodiments of sliding insert 164 are shown in FIGS. 9A-10B.

[0118] 7A shows a perspective view from the rear of seat post 160, which includes an abutment flange 166 at the free end (i.e., the end without the saddle) of seat post 160, which prevents seat post 160 from being completely pulled out of seat tube 130 (see, for example, FIG. 6B). Flange 166 is configured to abut against the lower edge of sliding insert 164 when seat post 160 is moved upward as far as possible.

[0119] Additionally, Figure 7A illustrates the intersection line AA of the cross section shown in Figure 7C. Additionally, seat post 160, manufactured by injection molding of reinforced thermoplastic material, includes a hollow profile with a plurality of protruding ribs 162 for engaging pin assembly 168 of locking assembly 145, which is preferably a quick-release locking assembly.

[0120] 7B shows a top perspective view of the seat tube 130. Note that the seat tube 130 has an at least partially non-circular interior cross-section that limits or prevents rotation of the corresponding seat post 160 about the seat post axis.

[0121] Figure 7C shows a cross-section taken along line AA in Figure 7A to illustrate the non-circular cross-section of seat post 160. When seat post 160 is moved upward, flange 166 abuts against the lower edge of a sliding insert, for example, as shown in Figure 9A.

[0122] FIG. 8 shows a perspective view of the pin assembly 168. This preferred embodiment includes two simultaneously pivotable and symmetrically arranged locking members, each having four pins 148. The locking members pivot about a pivot axis P. The entire pin assembly 168 is made of reinforced plastic. The pins 148 are configured to be moved through corresponding openings in the seat tube 130 so as to move from an open or released position (FIG. 9A) to an interlocked or locked position (see FIG. 9C). At least the tip or top of the picker 149 is configured to couple with the cam plate 146, thereby moving the picker along an elongated guide rail or aperture. This guided movement allows the pin assembly 168 to pivot from a released (open, FIG. 9A) position to a locked position (FIG. 9C).

[0123] FIG. 9A shows a perspective view of the pin assembly 168 along with a portion of the seat post 160, in which the seat post 160 is partially surrounded by a portion of the sliding insert 164. The pins 148 face the rear of the seat post 160 to interlock and interact with corresponding ribs on the outside of the seat post 160. To change the height of the seat post, the axially movable seat post 160 is guided into the sliding insert 164 located at the top of the seat tube 130. The outer diameter of the sliding insert 164, which includes two U-shaped elements 164U and 164u (see FIG. 10B), corresponds to the respective inner diameters of the seat tube 130. Furthermore, the inner circumference of the sliding insert 164 fits the outer cross section of the seat post 160 to ensure a perfect fit and smooth sliding when changing the saddle height.

[0124] Once inserted into the seat tube 130 (not shown in FIG. 9A here, but see, for example, FIG. 6B), the sliding insert 164 can be secured by at least one interengaging element 165. This interengaging element 165 can be configured as a resilient latch or a simple protruding element, is supported by an elongated member 135 extending circumferentially of the seat tube 130, and is at least partially flexible or resilient. A resilient means, such as the elongated member 135 of the at least one interengaging element 165, can be pushed toward the seat post 160 until it reaches a corresponding aperture 136 in the seat tube 130, and is configured to return the interengaging element 165 to a locked position within the seat tube aperture 136 due to the pretensioning force of the resilient means. The front element 164U may also be provided with two interengaging elements 165 (not shown, see, for example, FIG. 9C ) that can be received in or interengaged with corresponding apertures 136 in the seat tube 130 (see FIG. 6B ) to interlock the position of the sliding insert 164 relative to the seat tube 130.

[0125] Figure 9B shows a perspective view of the pin assembly 168 of Figure 9A after it has been moved toward the seat post 160, i.e., approaching the lateral ribs 162 of the seat post so that the four pins 148 eventually engage as shown in Figure 9C. The interlocked or locked position as shown in Figure 9C can be further secured by a spring element (not shown, see reference numeral 169 in Figure 10A).

[0126] 10A shows a preferred embodiment of a pin assembly 168 positioned in a recess 163 comprising the sidewall 144 of the rear 140 of the bicycle frame 100. The pin assembly 168 is spring biased toward a locked position by a spring element 169 (see arrow indicating force toward the seat post). This is advantageous because the spring element 169 ensures that movement toward the seat post 160 to engage corresponding recesses between ribs 162 of the seat post 160 (e.g., as shown in FIG. 10B).

[0127] 10A shows in detail the shape of recess 163, which has curved side walls 144 that are substantially circular (see the center of the circle with radial spokes behind pin assembly 168). At the bottom is a curved protrusion that receives the pivot portion of pin assembly 168 with pivot axis P. The generally circular shape of recess 163 is configured to allow the locking member with pin 148 to pivot sufficiently from seat tube 130 to release seat post 160 into the open or released position.

[0128] 10B shows a perspective view of the pin assembly with its associated cam plate 146 in a locked position and connected to the seat post 160. The cam plate 146 has a guide rail or aperture 137 for receiving a picker 149. Another cam plate 146 can be located on the opposite side. The cam plate 146 has a lever 147 integrally formed or attached to its outer surface (the side not visible in FIG. 10B (see FIG. 3A)) configured to pivot the pin assembly 168.

[0129] The sliding insert 164 includes a flange 176 that abuts the upper edge of the seat tube 130 when inserted into the seat tube 130. As previously mentioned, the sliding insert 164 has two U-shaped parts, a front section 164U and a rear section 164u, that are connected by having flanges to form the flange 176 that surrounds the entire upper end of the sliding insert 164. The larger U-shaped front section 164U surrounds a larger portion of the seat post 160 than the smaller U-shaped rear section 164u.

[0130] The rear element 164u of the sliding insert 164 is positioned at the rear and parallel to the rear surface of the seat post 160. The legs of the U-shape of the element 164u are at right angles parallel to each side wall of the seat post 160 and cover the rib 162. The rear element 164u has a protrusion 164p that is engageable with a corresponding aperture in the front element 164U like a lug. Such an aperture may be in the form of a slit 164s, as shown in FIG. 9C, configured to provide a releasable click connection to lock the two elements 164u and 164U of the sliding insert 164. After the sliding insert 164 is inserted into the seat tube 130, the click or snap connection between the at least one protrusion 164p and the slit 164s is further held in place by the corresponding inner surface of the seat tube 130.

[0131] Both elements 164U and 164u of sliding insert 164 have ribbed portions for added stability. Rear element 164u of sliding insert 164 has an aperture at the height of pin 148 to allow the pin to engage with a recess between ribs 162 of seat post 160.

[0132] The pin assembly 168 together with the cam plate 146 form a locking assembly 145, which is preferably a quick lock and release assembly using a spring element 169 as shown in FIG. 10A.

[0133] FIG. 10C shows a top perspective view of a portion of the seat tube 130 with the slide insert 164 attached and a portion of the pin assembly 168. The flange 176 completely surrounds the seat post 160 and, when inserted into the seat tube 130, can abut against the upper edge of the seat tube 130. In this way, the flange 176 covers any potential gaps between the seat post 160 and the seat tube 130. The slide insert 164 substantially surrounds the outer periphery of the seat post 160, extends parallel to the longitudinal axis of the seat post 160, and may be approximately 0.25 to 0.3 times the overall length of the seat post 160. This design offers the advantage of eliminating play between the components; i.e., the upper region of the inner surface of the seat tube 130 is below the flange 176 and fits snugly against the outermost surface of the slide insert 164. Furthermore, the inner surface of the seat post 160 can slide smoothly within the precisely manufactured inner periphery of the slide insert 164.

[0134] FIG. 10C shows a detailed cross-sectional view of the pin assembly 168 that is pivotable toward the seat post 160.

[0135] 11 shows a complete side view of a preferred embodiment of an electric bicycle 1100, in which the frame is formed as a single unit and manufactured by injection molding of reinforced thermoplastic material. The bicycle comprises a head tube 110 with a fork 190 and steering portion 195, preferably handlebars with handlebar grips, and a bicycle basket 104 above the front wheel 194.

[0136] The middle section 120 has an elongated cavity 125 formed therein for accommodating an energy storage unit 150, such as a battery, configured to store energy for power and electrical equipment. The seat post 160 is inserted into the seat tube 130 at a predetermined height. The middle section 120 includes a bottom bracket 121 having a crank arm 175 and cycle pedals 123. The crank arm 175 is configured to connect the pedals 123 to the bottom bracket 121, thereby transmitting pedaling power. The rear section 140 is configured to engage with a rear wheel 180, which may be 18 inches to 28 inches, preferably 24 inches, and further supports a luggage rack 114. A thermoplastic kickstand 174 is disposed on the rear section 140 and is pivotable; FIG. 11 shows the kickstand 174 folded upward. When the electric bicycle 1100 is parked in a parking position, the kickstand 174 can be folded downward (not shown).

[0137] Figure 12 shows a schematic diagram showing the electrical components of an electric bicycle 1100, including an integral frame 100, a front wheel 194, a rear wheel 180, and a fork 190 with fork blades 192. The main components are made of reinforced thermoplastic material. The vehicle control unit 115 (VCU) may also be called a central control unit. The VCU is designed to form a central junction, connecting all electrical components with cables, as shown schematically in Figure 12 and further illustrated in the plug connection diagram in Figure 13.

[0138] The central control unit 115 or vehicle control unit (VCU) is located in the central section below the energy storage unit 150, such as a battery BAT. Electrical components such as a front light or illumination 154, a backlight 156, a left indicator 185, a right indicator 186, and an actuator bicycle lock 189 can be controlled by the control unit 115. A human-machine interface (HMI) is connected to the control unit 115 via a cable. The HMI is configured for a mobile machine and can integrate one or more elements selected from the group including, for example, a display (HMI_D) including a screen and optionally buttons or a touchscreen; control elements (HMI_C) including, for example, a button unit, switches, or keys; and input elements such as lights, operating elements, and buttons. In this way, the HMI can have multiple interfaces. For example, the HMI can be used to display information about the electric bicycle, such as power, battery status, RPM, speed, GPS location data, etc.

[0139] A human-machine interface (HMI) may include a processor that can be used in addition to the control unit 115 (VCU) or as the control unit 115 itself. The control unit 115 (VCU) and / or the HMI may include at least one memory. Instead of or in addition to local memory, a cloud-based system 117 may be used to store data externally on a network or to collect data such as fleet infrastructure data for managing a fleet (reference numeral 118: fleet management).

[0140] The control unit 115 is connected to the IOT device, which acts as a gateway for a wireless network with other elements and services. The network can be realized, for example, via the Internet using a mobile network of a mobile device such as a smartphone, or it can be realized locally, for example, via Bluetooth or RFID. Furthermore, other functions can be integrated into the IOT device, such as GPS, LED connections indicating the status of at least one electrical component, motion or acceleration sensors, etc.

[0141] In this manner, electric bicycle operators can use the IOT device in conjunction with a mobile smart device to obtain data and provide tools for various purposes, such as fleet management 118. In a preferred embodiment, fleet management 118 can be cloud-based software that manages the vehicles in a fleet through access via the IOT device and includes multiple functions. For example, the location of the vehicles in the fleet can be monitored using fleet information such as the geographic location of the bikes in the fleet. Another function of fleet management 118 is to indicate the charging status of each vehicle. Finally, messages can be remotely displayed on the displays of selected vehicles.

[0142] Furthermore, the IOT devices and / or control unit 115 and optionally the HMI, preferably in combination with a cloud-based system (reference numeral 117), can provide applications and apps (see reference numeral 118) for the electric bicycle 1100. That is, at least one of said electric devices of the electric bicycle 1100 can be used to deploy one or more applications 128 or applets, such as Internet of Things (IoT) applications. Such IoT applications have the advantage of being highly customizable and allowing for predictive bicycle maintenance.

[0143] In this way, integration and optimization of smart city applications can be provided. Furthermore, the use of external data storage allows access to big data and the use of artificial intelligence software for data analysis. Applications 128 can be based on software and programs selectable from a group including fleet management software, operating system software and programs, software applications for Internet of Things (IoT)-enabled devices, network operating system programs, computer software that provides integrated management intelligence in real time by combining information from various databases and displaying it in easy-to-understand user interface software within the HMI, graphical user interface software, downloadable computer software applications, database management software, predictive maintenance software and interactive software, software for coordinating energy storage and consumption, and downloadable cloud computing software for connecting bicycle or mobile devices to a cloud computing platform. Using IoT, each device can collect important operator data and integrate this information to, for example, control generators and provide additional assistance when needed.

[0144] 12 also shows a so-called "diagnostic tool" 119 configured to read or receive diagnostic data for diagnosing one or more pieces of electrical equipment of the bicycle 1100. Furthermore, the diagnostic tool 119 is preferably configured to change settings and / or update software of the control unit 115. In this way, flash programming of the embedded software can be performed inside the vehicle ("in-line") without removing the control unit 115 from the e-bicycle 1100. The diagnostic tool 119 can be a processor with corresponding interface card or software.

[0145] An energy storage charging system 157 can be used to recharge the accumulator or battery (BAT) of the electric bicycle 1100. This charging system 157 can be a regular charging system or a high-performance charging system (HPC). If the bicycle is designed for high voltage, the battery (BAT) must be designed accordingly and thermal management must be taken into consideration. Regardless of the battery type, it is preferable to provide the VCU 115 with a battery management system. In this way, the battery utilization of the electric bicycle can be optimized and battery damage can be avoided.

[0146] The voltage of an energy storage unit 150, such as a battery (BAT), can also be charged by a pedal alternator 153, in which the operator uses both feet to activate pedals that drive the alternator 153. The latter is also referred to as a pedal generator, which generates power using a physical input. In a preferred embodiment, a voltage regulator, either integral with or separate from the alternator 153, can be provided that is configured to control the output of the alternator 153 according to the desired voltage level of the battery. The desired voltage level to which the energy storage unit 150 is charged depends on the temperature of the battery (BAT); at high temperatures, the battery needs to be charged to a lower voltage than at sub-freezing temperatures. To account for this temperature dependency, the voltage regulator is connected to a temperature-sensing device positioned so that the battery's temperature can be accurately measured.

[0147] The electric bicycle 1100, preferably a pedelec (pedal-powered electric bicycle), is power-assisted and can be propelled by supplementing pedaling force with electric power supplied by an electric motor 151 located at the hub of the rear wheel 180. Alternatively, the electric motor 151 can be located on the front wheel 194. One method of assisting pedaling is typically to provide a power combiner mechanism for combining the pedaling force introduced by the pedals with the electric power of the electric motor 151.

[0148] Although a chain is usually used to transmit the pedaler's power to the wheel, alternative solutions without a chain are also possible. This has the advantage of saving space and avoiding complex structures and chain maintenance. The rotation speed of the electric motor 151 can be controlled by the control unit 115 based on a pedal speed sensor configured to sense the pedal speed. That is, the vehicle control unit 15 controls the current supplied to the motor 151 so that the rotation speed of the rear wheel 180, which corresponds to the rotation speed of the motor 151, follows the pedal speed. Furthermore, a pedal torque can be calculated based on the pedal speed, which can also be used as an input for controlling the electric motor 151.

[0149] FIG. 13 shows a schematic diagram of the connections between the bicycle components, including the electrical components, of the electric bicycle 1100 shown in FIG. 12. The control unit 115 is central. For safety reasons, the control unit 115 is electrically connected to the battery lock 152 as well as the actuator of the bicycle lock 189. The energy storage unit 150 includes two batteries BAT1 and BAT2. Each of the batteries can power a human interface component, such as an HMI controller, such as a button unit (HMI_C) or a display (HMI_D). To charge the batteries, either the charging connection 157 or a connection to the alternator 153 can be used. The system architecture shows an optional second electric motor 151' as a preferred embodiment, which can support, for example, the wheel axle of a trailer. In this way, the system is particularly suitable for cargo bikes.

[0150] Further components not shown, such as temperature sensors or sensors capable of measuring information about the wear or failure of various bicycle components, can be connected to the control unit 115. In a preferred embodiment, an injection molding manufacturing method is used, which advantageously provides sensors embedded in the thermoplastic material, especially in areas of increased load.

[0151] Figure 14 shows a partial perspective view of the bicycle frame to at least partially illustrate the guidance of the cables. Reference numeral 108 denotes the cables and internal frame routing within the mid-section 120. The partial view also shows a cable 172 guided inside the rear section, connecting the electric motor 151 to the energy storage 150, which is also connected to the pedal alternator 153. The cables 108 and 173 of the mid-section 120 are partially routed in parallel, designed to split a single wire into multiple wires to supply various consumers, e.g., lights, HMI, IOT, etc.

[0152] 15 shows a front (left) and side view of a bicycle frame 100, the load case of which includes a steerer tube 191 and a seat post 160 with a saddle 161. The calculations assume a maximum total bicycle weight of 160 kg, including rider and luggage. A maximum total bicycle weight of up to 250 kg is assumed for standard tests according to DIN 79010:2020-2.

[0153] Fiber-reinforced thermoplastic materials are ideal when high stiffness is required. Therefore, stiffness was one of the primary design goals. Depending on the load criteria placed on the bicycle frame components, additional reinforcement can be added as needed. Bicycle frame 100 further utilizes structural reinforcements, such as ribs or inserts, to meet load cases, as shown in FIG. 15.

[0154] The load cases are simulated based on the design of the individual components and are minimum loads, and a security or safety factor of at least 1.5 can be assumed. That is, the bicycle frame 100 or bicycle components, such as the fork 190, are actually stronger than necessary for the loads shown in FIG. 15 . The load cases are for an exemplary embodiment of a bicycle frame 100 suitable for use with 24-inch wheels. This bicycle frame 100 preferably has a frame height H2 of approximately 445 mm, e.g., dimensions similar to those shown in FIG. 2B . The characteristic maximum weight of the bicycle frame 100 without inserts is approximately 8040 g. The seat post used in the following load cases and simulations weighs approximately 470 g.

[0155] On the left side of Figure 15, a front view of bicycle frame 100 is shown. When steering tube 191 is inserted into head tube 110 of bicycle frame 100, a typical vertical load case is an expected or simulated force F1 of an operator steering the bicycle, which is directed vertically downward from both sides of steering portion 195 (shown diagrammatically). Steering portion 195 can be designed as a handlebar (see, for example, Figure 11).

[0156] Load case F1 can reach a maximum of 1000 N and can be split into two forces located at opposite ends of steering portion 195.

[0157] To measure the resistance of the frame stiffness, the lateral forces that may be introduced when standing up from the saddle are also taken into account. The bottom bracket 121 of the bicycle frame's midsection 120 is shown with equal load cases F2 and F3 acting symmetrically downward on both sides of the bicycle frame 100. These load cases F2 and F3 simulate the so-called "weighing ride" (German: "Wiegetritt"), in which the bicycle is ridden while standing up from the saddle. This load is higher than the more stable case in which the rider rides while seated. F2 and F3 are each approximately 1300 N, indicating sufficient bottom bracket or standing ride stiffness for the bicycle frame of the present invention.

[0158] It should be noted that the components of the electric bicycle according to the present invention meet at least the necessary standards and pass relevant tests, such as Part 6 "Frame and fork test methods" of EN 15194 and DIN 79010 for cargo bikes. These tests must meet the requirements for the fork according to the test according to DIN 79010:2020 450 N. The bicycle frame 100 according to the present invention complies with the DIN 79010:2020 standard for dynamic testing with pedaling forces, which can be up to a load of approximately 1200 N.

[0159] The homogeneity of the thermoplastic material allows for reliable calculations and simulations. Simulation results show that the following laterally acting forces on the bottom bracket 121 caused by torque can be satisfied by the present design: M1 is the brake torque of 300Nm. M2 is the torque at the torque support, directed axially parallel to the axis of the front wheels.

[0160] By providing lateral stability, vibrations while riding the bike can be minimized.

[0161] For bicycle frame 100, load case F5 at the bottom of steerer tube 191 is absorbed by support 178, which has two translational degrees of freedom in the y and z directions. Simulations have shown that the reinforced thermoplastic material of support 178 can absorb a force F5 of approximately 1200 N under normal loads. Additionally, a bicycle basket can be optionally attached to head tube 110, allowing four mounting points on each of the bicycle basket's four mounting points to be attached while maintaining stability. * 150N = 600N, i.e., load case F4 of 150N can be assigned.

[0162] The loads of the sprocket and crankshaft of the bottom bracket 121 are introduced into the bicycle frame 100 at the metal inserts connecting the bottom bracket 121 to the bicycle frame 100 (see FIG. 2A for an exemplary embodiment with six metal inserts). These connection points of the bottom bracket in the central section 120 experience both a force F6 and a torque M3. In the simulated load case, assuming force F6 is transmitted to the lowest pedal when the operator's full weight is applied, the normal force of the user-dependent bottom bracket force F6 is 1300 N (132 kg). Additionally, a maximum of 200 Nm of counter torque M3 from the generator (not shown) can be absorbed by the thermoplastic material near the bottom bracket 121. The bottom bracket force F6 and torque M3 are directed to each of a number of metal inserts 122 (see FIG. 2A), preferably four to six, positioned around the circular opening of the bottom bracket 121 to secure the crankshaft.

[0163] The saddle post can absorb a saddle load case F9 of 2000N (corresponding to a maximum of approximately 204kg). This corresponds to the required stability of the saddle post according to strength tests in accordance with DIN 79010. The saddle post locking also meets the requirements of DIN ISO 4210-9, e.g. the dynamic test criteria according to 4.4 with a load of 1000N and 200,000 load cycles.

[0164] Simulation results according to the present invention show that the safety requirements of the bicycle frame 100 can be met when a 24-inch wheel shape is assumed. The electric bicycle is further designed as a cargo bike and has a support 179 at the rear with three translational degrees of freedom in the x, y and z directions.

[0165] Load case F7 represents the tensile load taking into account acceleration or deceleration, respectively, when the maximum weight of the attached trailer is 60 kg. Load F7 safely absorbs a force of approximately 270 N (28 kg). The rear 140 can absorb a maximum load case F8 for luggage, totaling 600 N (approximately 61 kg). That is, if there are four support elements 113 for the luggage rack (two on each side), F8 = 4 * The total load capacity is 150 N, with an additional payload of 600 N when acceleration is taken into account. Tests on the potential connection to a trailer have shown that the requirements of tests similar to DIN 15918:2017:05 are met. The bicycle frame is therefore particularly suitable for use on cargo bikes.

[0166] The Cargopedelec's design complies with the DIN 79010 (Cycles - Transportation bikes and cargo bikes - Requirements and test methods for single- and multi-track cycles) standard for cargo bikes, and therefore does not exceed a maximum permitted weight of 300 kg. DIN 79010 also refers to electric assist bicycles (maximum rated power of 250 W and cut-off speed of 25 km / h).

[0167] Kickstand load case F10 of up to 1800N was simulated in the parked position with the kickstand extended.

[0168] FIG. 16 illustrates a manufacturing method for the bicycle frame 100. Producing the complex rib structure and apertures or recesses from a single piece requires not only the use of a single mold but also the use of multiple sliders. By using sliders during injection molding, even the most complex 3D structures of the bicycle frame 100 can be easily realized in large quantities. The following sliders are used: sliders 110s for manufacturing the head tube, sliders 120s for manufacturing the bottom cavity of the midsection, sliders 125s for manufacturing the energy storage cavity 125, sliders 130s for manufacturing the seat tube, and sliders 140s for manufacturing the rear cavity. The arrows indicate the direction in which the sliders are removed after the injection molding process. Note that the sliders may have a foldable core.

[0169] According to a preferred embodiment, the method further comprises the step of connecting one or more metal or plastic inserts in areas of higher mechanical loads by back-molding at least a portion of one or more inserts for a press-fit and / or form-fit connection. Additional reinforcing components such as metal inserts can be provided in a single mold for the bicycle frame, and by using sliders and preferably self-folding cores together, off-tool bicycle frames can be mass-produced with excellent precision. In this way, a manufacturing method is provided that can provide off-tool bicycle frames without foreseeing further process steps.

[0170] In conclusion, the bicycle frame 100 according to the present invention has excellent stability characteristics and can be used in a wide range of applications, including cargo bikes. Using injection molding technology for components of electric bicycles, such as the bicycle frame and fork, allows for the production of relatively high-strength parts capable of withstanding load cases such as those described above in connection with FIG. 15, meeting the requirements of DIN 79010 for cargo bikes and EN 15194 and / or ISO 4210 for e-bikes. Furthermore, the bicycle has an aesthetically pleasing appearance, and in combination with a cover, the complex structure can be further protected from dirt and other elements. By providing cavities and electrical connections, the bicycle can receive an energy storage unit and be operated electrically. Furthermore, advantageously, an alternator or generator can be used to charge a rechargeable energy storage unit, such as a battery. Because the bicycle frame and fork according to the present invention meet high safety requirements, the bicycle can be used as a road bike. In particular, the bicycle frame and fork are suitable for use in fleet bikes, as they can be rapidly manufactured in large quantities by injection molding and are easily maintained during operation. [Explanation of symbols]

[0171] 100 Bicycle Frame 101 Inserts for mounting parts such as brakes or axles 102 Middle rib 103 Longitudinal Strips 104 Bicycle Basket 105 Rib perpendicular to circumferential rib 106 Circumferential rib 107 Bearing for kickstand 108 Intermediate section cable and cable internal frame routing 109 Cable 110 head tube 111 Head tube upper metal insert 112 Lower metal insert in head tube 113 Luggage rack support elements 114 Luggage Rack 115 Control Unit 116 Rear partial cover 117 Network - Fleet Infrastructure 118 Smartphones and other smart devices 119 Diagnostic Tools 120 Middle part 121 Bottom Bracket 122 Insert for bottom bracket for fixing crankshaft 123 Cycle Pedals 125 cavity 130 seat tube 134 Seat tube opening for locking assembly 135 Elongated member supporting interengaging element 165 136 Holes for receiving interengaging elements 165 of the slide insert 137 Guide rail or aperture for receiving picker 149 140 rear 141 Rear wheel bearing 142 Rear Rib 143 screw holes for luggage rack 144 Side walls of recesses or receptacles 145 Locking assembly including at least a pin 148 and a cam plate 146 146 Cam plate with guide rail on the underside 147 Lever connected to cam plate 148 pins 149 Pin Assembly Picker 150 Energy storage, e.g., a battery 151 Electric motor 152 Battery Lock 153 Alternator or generator 154 Front Light or Lighting 155 Cover for energy storage cavity 156 Backlight or Illumination 157 Charging connection 158 Charging Station 159 Rear 140 polygonal window 160 seatpost 161 Saddle 162 Transverse ribs for interengagement with pins 163 Recess 164 Slide Insert 165 Interengaging Elements 166 Abutting flange 167 Notch 168-pin assembly 169 Spring Elements 170 Plastic inserts in bicycle frames made of stiffer plastic than thermoplastic materials 171 Metal Insert 172 Rear internally guided cable 173 Cable 174 Kickstand 175 crank arm 176 Upper flange of slide insert 178 Support for two translational degrees of freedom (y and z directions) 179 Support for three translational degrees of freedom (x, y, and z directions) 180 rear wheel 181 Internally guided cable in intermediate section 120 182 Internally guided cables to rear wheels containing electric motors 183 Front wheel brake 184 Rear wheel brake 185 indicator left 186 indicator right 187 Actuator Front Brake 188 Actuator Rear Brake 189 Actuator Bike Lock 190 Fork 191 steering tube 192 Fork Blade 193 Plastic Insert 194 front wheel 195 steering part formed as handlebar 196 Rib to limit steering angle 102l Longitudinal rib 102t Transverse rib relative to the longitudinal axis m of the middle section 103x X-shaped strips Sliders for manufacturing 110s head tubes 120s Slider for manufacturing the bottom cavity of the middle part 125s Battery Cavity 125 slider for manufacturing Slider for manufacturing 130s seat tube 140s Rear cavity manufacturing slider 164u Rear element of slide insert 164 164U Front element of slide insert 164 164p, the protrusion of the rear element 164u inserted into 164s 164s: Slit for connecting the rear element 164u and the front element 164U a Head tube longitudinal axis b Longitudinal central axis of the energy storage cavity c longitudinal axis of the seat tube d Vertical axis passing through the center of the rear wheel aperture m Longitudinal axis of middle section r An axis parallel to the rear wheel axis passing through the center of the rear wheel aperture x Horizontal axis through the center of the bottom bracket x1 Horizontal axis passing through the center of the rear wheel aperture y Vertical axis through the center of the bottom bracket α is the angle between the head tube axis a and axis d β is the angle between the longitudinal axis c of the sheet tube and the vertical axis y δ is the angle between the longitudinal axis b and the longitudinal axis m of the cavity BRK_F / R Brake-front / right P axis IOT Internet of Things HMI Human Machine Interface Lock Electric bicycle locking system AA intersection line H1 Height between the center of the bottom bracket and the center of the bottom of the head tube H2 Height between the center of the bottom bracket and the center point of the top of the seat tube W1 Width between rear wheel hub and head tube W2 Distance between the center of the bottom bracket and the center of the seat tube F1 Forces directed vertically downward from both sides of the steering F2 Force at the first fork end F3 Force at the second fork end opposite the first fork end F4 The Power of Bicycle Basket F5 Force of a fork with two translational degrees of freedom (y direction / z direction) F6 Bottom bracket force transmitted to lowest pedal F7 Trailer Power F8 Rear load force F9 Saddle force F10 kickstand power M1 Torque Brake M2 Torque Support M3 Generator counter torque

Claims

1. A bicycle frame (100) for an electric bicycle, formed in one piece and manufactured by injection molding of a reinforced thermoplastic material, comprising: The integral structure comprises: A head tube (110); a seat tube (130) preferably having a seat post receiving portion configured to receive a seat post (160); an intermediate portion (120) connecting the head tube (110) and the seat tube (130); a rear portion (140) configured to engage the rear wheel; Including, The intermediate portion (120) is formed with a bottom bracket (121), A bicycle frame having an elongated cavity (125) formed in either the middle portion (120) or the rear portion (140) configured to accommodate at least one energy storage unit for power and / or electrical equipment.

2. the elongated cavity (125) is disposed in the intermediate portion (120) between the bottom bracket (121) and the head tube (110), and the energy storage unit (150) includes at least one battery; 2. The bicycle frame of claim 1, wherein the elongated cavity (125) is configured such that the outermost periphery of the battery about the central longitudinal axis of the battery is completely surrounded by the intermediate portion (120).

3. 3. The bicycle frame of claim 1, wherein a plurality of reinforcing ribs are provided on at least one of the intermediate portion and the rear portion, the rear portion being further configured to support a luggage rack.

4. 4. A bicycle frame according to claim 1, wherein the reinforced thermoplastic material comprises at least one reinforcing component selected from the group consisting of carbon fibres, glass fibres, natural fibres, carbon nanotubes or combinations thereof, and optionally the bicycle frame comprises areas with a higher fibre to thermoplastic material weight ratio in order to support higher mechanical loads.

5. the glass fiber content of said reinforced thermoplastic material is 20-65 wt. %, preferably 50 wt. %; 5. A bicycle frame according to claim 4, wherein the thermoplastic material is chosen from PA6, PA6.6 or mixtures thereof, at least in areas subject to higher mechanical loads.

6. at least one metal insert (111, 112) and / or at least one plastic insert (170) made of a plastic more rigid than the reinforced thermoplastic material of the bicycle frame is connected to the reinforced thermoplastic material of the bicycle frame by injection molding; Said metal or plastic insert (170) preferably comprises the following components: The head tube (110), the seat tube (130), the bottom bracket (121), rear wheel bearings, brake calipers and luggage rack (114) 6. A bicycle frame according to any one of claims 1 to 5, wherein the bicycle frame is located on or near one or more of:

7. 7. The bicycle frame according to claim 6, wherein the plastic insert for the support element of the rear wheel (180) comprises apertures for injection molding and form-fit connection, and is optionally adapted to receive a brake element.

8. 8. The bicycle frame of claim 1, further comprising a pin assembly on the seat tube having at least one movable pin configured to engage a corresponding recess in the seat post to lock the seat post at a predetermined height.

9. 9. The bicycle frame of claim 8, wherein the rear portion (140) comprises a rear wheel hub support and at least one of a luggage rack (114) and / or a recess (163) for accommodating at least a portion of the pin assembly (168) and a lever (147) configured to move the at least one pin (148) of the pin assembly (168) through a corresponding opening in the seat tube (130).

10. the pin assembly is a pivotable pin assembly that forms a quick release locking assembly with a cam plate (146) and is made of a reinforced thermoplastic material; 10. The bicycle frame of claim 9, wherein the lever (147) is movable from a released position to a locked position and is configured to be coupled to the pivotable pin assembly including the at least one pin (148) via the cam plate (146), the cam plate (146) defining an elongated guide rail or aperture, a picker (149) of the pivotable pin assembly is movably coupled to the cam plate (146) to move the pivotable pin assembly within and constrained by the guide rail or aperture from the released position to the locked position, the pivotable pin assembly preferably being spring biased toward the locked position by a spring element (169).

11. 11. A bicycle frame according to any one of claims 1 to 10, wherein the seat tube (130) has an at least partially non-circular internal cross section such that the rotation of the corresponding seat post (160) about the seat post axis is limited or prevented.

12. 12. The bicycle frame according to claim 1, wherein a sliding insert (164) is configured to guide the axially movable seat post (160) into the sliding insert (164) disposed in an upper portion of the seat tube between an inner diameter of the seat tube and an outer diameter of the seat post (160).

13. 13. A bicycle frame according to any one of the preceding claims, wherein the head tube further comprises at least one bearing bush and is configured to receive the corresponding steerer tube (191) of a front fork made of metal and / or thermoplastic material.

14. The electrical equipment of the electric bicycle is a cable guided at least partially within the bicycle frame; an electric drive unit including an electric motor (151), optionally a chainless drive system; Energy storage management systems, Brake control system, a central control unit (115); at least one processor; at least one memory, optionally containing one or more applets; at least one user interface; a communication interface for diagnostic tools and / or the Internet; Multiple lights, Auto-lock, and Multiple Indicators 14. A bicycle frame according to any one of claims 1 to 13, comprising at least one of:

15. 1. A seat post manufactured by injection molding a reinforced thermoplastic material, the seat post being formed of a unitary construction and configured to be received by a seat tube (130) of a bicycle frame (100) manufactured by injection molding a reinforced thermoplastic material, The seat post includes a hollow profile having a plurality of protruding ribs (162) for interengaging with at least one pin (148) of a locking assembly (145) disposed on the seat tube (130).

16. the hollow profile has a U-shaped cross section including transverse ribs dividing the hollow profile into segments; 16. The seatpost of claim 15, wherein the protruding rib (162) is configured to interengage with at least one pin or pins of the locking assembly (145), and the protruding rib (162) is disposed laterally on an outward-facing side of a free end of the hollow profile.

17. 17. The seat post of claim 16, wherein the seat post is further guideable within a sliding insert (164) fixed to the upper part of the seat tube via at least one interengaging element (165), and the seat post (160) further comprises a flange (166) at the free end of the seat post configured to abut against a lower edge of the sliding insert (164), thereby preventing complete withdrawal from the seat post.

18. A method of manufacturing a bicycle frame (100) having a unitary structure, comprising the steps of: Reinforced thermoplastic materials are injection molded using a single injection tool, A head tube (110), a seat tube (130), a middle section (120) in which a bottom bracket (121) is formed, and a rear section (140). Integral forming a unitary structure comprising: providing and withdrawing a plurality of sliders (110s, 120s, 130s, 140s, 150s) from the injection tool at the head tube (110), the seat tube (130), the middle section (120) and the rear section (140) to form the head tube (110), the seat tube (130) and an elongated cavity configured to accommodate an energy storage unit (150), preferably including at least one battery; A method comprising:

19. 20. The method of claim 18, further comprising the step of connecting one or more inserts of metal or plastic to areas of higher mechanical load by injection molding, and optionally back-molding at least a portion of the one or more inserts through apertures for connection by press fit and / or form fit.

20. An electric bicycle (1100) having a bicycle frame (100) according to any one of claims 1 to 14, further comprising a rear wheel (180) and a fork (190) connected to the front wheel and a steering portion (195), wherein the fork (190) is an integral part made of reinforced thermoplastic material, or the fork (190) comprises metal and thermoplastic material, and a steering tube (191) of the fork (190) is made of metal.

Images