Bicycle Frame Integral Fastener Passage for Cable Routing
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Solution Overview
Problem
Existing bicycle frame designs face challenges in securely and compactly routing control cables and accessories without complicating the frame's design, manufacture, or affecting aerodynamics, and often require complex internal routing that complicates assembly and serviceability.
Innovation Solution
The integration of a passage system within the bicycle frame's elongate tubes, featuring a partition and bridge that forms a flush inlet and outlet for secure cable or accessory mounting, using a flexible connector like a cable tie, which is toolless and minimally invasive, allowing for easy interaction and secure attachment of control elements and accessories.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If complex internal routing is used to route control cables and accessories through the frame, then cable routing security is improved, but assembly and serviceability complexity increases
Solution Approach 1:
The internal routing passage is segmented into distinct sections: an inlet passage portion, a intermediate portion, and an outlet passage portion. This segmentation allows for organized cable routing while maintaining structural integrity and simplifying assembly by breaking down the complex routing into manageable segments.
Solution Approach 2:
The routing passage is nested within the elongate tube structure of the frame member, utilizing the hollow interior space. This nesting approach provides secure cable routing without adding external complexity, as the passage is integrated within the existing frame tube geometry.
2Reliability
If mounting structures are added to the frame for cable and accessory attachment, then mounting security is improved, but aerodynamic performance deteriorates
Solution Approach 1:
The mounting structure is merged with the frame member itself, using the elongate tube as both a structural component and a mounting surface. The cable tie engagement features are integrated directly into the tube wall, eliminating separate mounting brackets that would compromise aerodynamics while maintaining secure attachment capability.
Solution Approach 2:
The mounting features are localized to specific regions of the elongate tube where cables need to be secured. The tube wall includes localized engagement structures (such as recesses or protrusions) that provide secure mounting points only where needed, leaving the rest of the frame surface smooth and aerodynamic.
3Ease of manufacture
If traditional cable routing methods are used, then ease of manufacture is maintained, but design complexity increases
Solution Approach 1:
The routing passage and mounting features are pre-formed as integral parts of the elongate tube during the frame manufacturing process. This preliminary action eliminates the need for post-assembly modifications or separate installation steps, maintaining manufacturing simplicity while achieving the desired cable routing functionality.
Solution Approach 2:
The elongate tube serves multiple functions: it provides structural support, contains the routing passage for cable management, and includes integrated mounting features for securing cables and accessories. This multi-functionality reduces design complexity by consolidating multiple features into a single component rather than requiring separate elements.
Data Source
AI summary
A method for forming a bicycle frame assembly having a number of elongate tubes is disclosed. A two part mold can be used to form a hollow finish part as part of the assembly. The assembly includes a passage that is defined by the elongate member, a partition, and a bridge. The partition isolates the passage from an interior volume of the elongate tube. The bridge extends in a direction normal to an elongate direction of the passage and defines an inlet and an outlet of the passage. The inlet, outlet, and bridge are generally flush with an exterior surface of the elongate tube and provide a passage that cooperates with a flexible connector, such as a cable tie, for securing supplemental structures, such as brake and shift control cables, to the elongate tube of the bicycle frame assembly.