Bicycle Frame Bonding Structure for Thermal Deformation Compensation
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Solution Overview
Problem
Conventional bicycle frame production faces increased costs and reduced productivity due to the need for various sizes and correction operations for thermal deformation in stamping frames, particularly in forming the front triangle portion using a mold and making the rear triangle portion in one size for common use.
Innovation Solution
A bicycle frame structure where the rear frame's left and right stays are bonded with an insert portion, and the front frame has a head tube with an insertion hole for the insert portion, allowing for a predetermined gap and inward bending to improve the connection structure, enabling the use of a common rear frame for various front frame sizes and enhancing rigidity and productivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the front triangle portion is made using a mold and the rear triangle portion is made in one size for common use, then production costs are reduced, but correction operations for thermal deformation in the bonding portion must be performed, reducing productivity
Solution Approach 1:
The patent applies preliminary action by pre-forming the front triangle portion with built-in compensation for thermal deformation. The bonding portion is designed with predetermined geometric features that anticipate and compensate for expected thermal expansion/contraction during the bonding process, eliminating the need for post-bonding correction operations and thereby maintaining high productivity while keeping production costs low.
Solution Approach 2:
The patent employs parameter changes by modifying the geometric parameters of the bonding portion to account for thermal deformation. The bonding surfaces are designed with specific angles and tolerances that compensate for thermal effects, allowing the front and rear triangle portions to bond accurately without requiring corrective operations after bonding.
2Adaptability or versatility
If various sizes of frames are produced through stamping forming, then different size requirements are met, but production costs increase
Solution Approach 1:
The patent applies segmentation by dividing the bicycle frame into two distinct modules: a rear triangle portion that is standardized and produced in one size for common use, and a front triangle portion that is manufactured in various sizes to meet different requirements. This segmentation allows the majority of the frame (rear triangle) to be produced efficiently in a single configuration while only the front triangle requires size variation, significantly reducing overall production costs while maintaining adaptability.
Solution Approach 2:
The patent implements universality by designing the rear triangle portion as a universal component that can be used across multiple frame size configurations. The standardized rear triangle with its specifically designed bonding portions can be paired with different front triangle sizes, creating a multi-functional system that reduces the total number of unique parts needed and lowers production costs.
3Productivity
If the rear frame is used for common sizes and the front frame is made to specific sizes, then productivity is improved, but the connecting structure of front frame and rear frame must be improved
Solution Approach 1:
The patent applies the nested doll principle by designing the bonding portion where one component is inserted into another. The front triangle portion features bonding surfaces that nest within or onto the rear triangle portion, creating a hierarchical assembly structure. This nesting approach simplifies the connecting structure by providing self-aligning features and reducing the complexity of joining operations, thereby maintaining improved productivity from modular production.
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
This solution reduces production costs and improves the rigidity and productivity of the frame by allowing the rear frame to be used for common sizes while enabling the front frame to be made to specific sizes, facilitating easier production and adjustment of angles.
Implementation Method 1
a first bonding portion is formed between a left stay inner panel and a right stay inner panel along a central axis between the left stay and the right stay
Implementation Method 2
a second bonding portion connected with an upper end portion or a lower end portion of the first bonding portion, may be formed between the left stay outer panel and the left stay inner panel
Implementation Method 3
the bent portions having the first radius are line-contacted with each other to form a pivot point
Data Source
AI summary
A bicycle frame structure having a rear frame and a front frame includes a rear frame of which a left stay and a right stay are bonded to each other, and an insert portion is formed at a bonded end portion, and a front frame where a head tube is formed at a front end portion thereof, an insertion hole into which the insert portion is inserted is formed at a rear end portion thereof, and the front frame is bonded to the rear frame along the circumference of the insertion hole.