Bicycle Front Fork Clamping Base Integral Manufacturing

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Solution Overview

Problem

Existing methods for manufacturing bicycle front forks with a clamping base face challenges in integrating a solid structure for vibration and impact resistance into a hollow fork design, leading to weak bonding or welding areas, complex and costly processes, and poor appearance.

Innovation Solution

A method involving the extrusion and molding of aluminum alloy substrates to form integrally connected round tubes with assembling segments, allowing for a solid clamping base without bonding or welding, and incorporating bumps for brake locking, ensuring structural integrity and aesthetic finish.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If the clamping base is made with a solid structure to enhance resistance to vibration and impact, then the strength and reliability are improved, but the weight increases and conflicts with the hollow fork tube design

Engineering Contradiction:

Improveresistance to vibration and impactVSAvoidweight of clamping base

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

The clamping base is integrated with the hollow fork tube through bonding or welding, merging two separate structures into a unified assembly. This allows the clamping base to maintain its solid structure for strength while the fork tube remains hollow for weight reduction, resolving the contradiction between strength and weight

Inventive Principle:

Principle #5Merging (Combining)

2Stability of the object's composition

If the clamping base is bonded or welded to the fork tube, then the structural integration is achieved, but the bonding or welding area is prone to broken under vibration and impact

Engineering Contradiction:

Improvestructural integrationVSAvoidstructural strength at bonding area

Core Design Contradiction:

Stability of the object's compositionVSReliability

Solution Approach 1:

Inventive Principle:

Principle #5Merging (Combining)

3Ease of manufacture

If the clamping base is bonded or welded to the fork tube, then the assembly is completed, but the manufacturing procedure becomes complicated and time-consuming

Engineering Contradiction:

Improveassembly completionVSAvoidmanufacturing procedure complexity

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The clamping base and fork tube are prepared in advance as separate components with predetermined bonding surfaces, allowing for standardized bonding procedures. This preliminary preparation simplifies the overall manufacturing process by enabling modular assembly rather than complex integrated fabrication

Inventive Principle:

Principle #10Preliminary action

4Ease of manufacture

If the clamping base is bonded or welded to the fork tube, then the assembly is completed, but the appearance is poor due to bonding or welding signs

Engineering Contradiction:

Improveassembly completionVSAvoidappearance quality

Core Design Contradiction:

Ease of manufactureVSShape

Solution Approach 1:

The bonding or welding operation is extracted as a separate, discrete step in the manufacturing process, allowing for specialized techniques that minimize visible signs. The bonding surfaces are specifically designed and prepared to create clean, minimal visible joints that preserve aesthetic appearance

Inventive Principle:

Principle #2Taking out (Extraction)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The method enables a bicycle front fork with a solid clamping base to withstand significant vibrations and impacts while eliminating the drawbacks of traditional bonding or welding methods, such as complexity, cost, and appearance issues.

Implementation Method 1

extruding the aluminum alloy substrate to have three rectangular bars integrally connected in a radical orientation

Methodology Applied

Scientific EffectExtrusion: Extrusion

Implementation Method 2

placing the blank into a first mold for forging the three rectangular bars into three round bars

Methodology Applied

Scientific EffectForging: Compression

Implementation Method 3

drilling the three round bars along the guide holes to form three round tubes communicated with one another

Methodology Applied

Scientific EffectDrilling:

Implementation Method 4

flattening and shrinking openings of two of the three round tubes

Methodology Applied

Scientific EffectFlattening: Compression

Data Source

PatentUS9579709B2Method for manufacturing bicycle front fork having wheel clamping base

Publication Date: 2017.02.28 ALEX GLOBAL TECH

AI summary

A method for manufacturing a bicycle front fork having a wheel clamping base. The method includes the steps of extruding an aluminum alloy substrate having three rectangular bars, wherein the two of the rectangular bars have assembling segments; cutting the substrate for a blank and placing it into a mold for forging the three rectangular bars into three round bars; placing the blank into another mold for extruding and punching the three round bars to have guide holes; drilling the round bars along the guide holes to form three round tubes; flattening and shrinking openings of two of the three round tubes; molding the assembling segments; downwardly bending the two round tubes having the assembling segments into two fork tubes of a bicycle front fork; punching the assembling segments into locking connection portions for a clamping base of the bicycle front fork.