Composite Bicycle Frame Joints for Precise Geometry Control
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Solution Overview
Problem
Existing methods for manufacturing bicycle frames from composite materials are time-consuming, costly, require excessive material use, and lack precise control over frame geometry, particularly in tailored production.
Innovation Solution
A method involving the use of a joint element made of cured resin inserted inside tube parts, which is cured while held in position by an expandable support, eliminating the need for a wrapping process and allowing for precise control over frame geometry and reduced material use.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the wrapping process with pre-impregnated bandages and filler is used to join tube parts, then the frame can be manufactured with composite materials, but the production time increases and costs increase
Solution Approach 1:
The invention extracts and eliminates the filler material and wrapping bandages from the traditional joining process. Instead of using multiple layers of pre-impregnated bandages and filler R as shown in the prior art, the patent uses a simplified joint element that achieves the same structural integrity without the excessive material layers, thereby reducing production time and complexity
Solution Approach 2:
The joint element is divided into distinct functional zones: an expansion zone for material deposition, a coupling zone for connecting tube parts, and insertion ends for fitting into tube openings. This segmentation allows for precise material placement and curing control, reducing overall production time while maintaining strength
2Strength
If the wrapping process with multiple bandages and filler is used, then the tube parts can be joined, but the material use increases causing frame weight increase
Solution Approach 1:
The invention removes the filler material and excess wrapping bandages from the traditional process. The joint element uses only the necessary amount of pre-impregnated material concentrated in the coupling zone, eliminating the weight penalty associated with multiple layers of bandages and filler while maintaining adequate connection strength
Solution Approach 2:
The pre-impregnated material is applied locally only where needed - in the coupling zone of the joint element where the tube parts connect. This localized application ensures strength at the critical joint area without adding unnecessary weight throughout the entire frame structure
3Ease of manufacture
If the traditional wrapping process is used to join tube parts, then the frame can be assembled, but the manufacturing precision and geometrical control are insufficient
Solution Approach 1:
The joint element is pre-formed with the exact geometry and dimensions required for the specific frame design. The insertion ends are pre-cut to precise lengths, and the coupling zone is pre-shaped to ensure accurate alignment. This preliminary preparation eliminates the need for complex adjustments during assembly, achieving both ease of manufacture and high manufacturing precision
Solution Approach 2:
The invention changes the physical state of the material from rigid pre-formed components to a pre-impregnated material that can be expanded and cured in place. This parameter change allows the joint element to adapt to precise geometric requirements during the curing process, achieving accurate frame geometry while simplifying the assembly process
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 results in a sturdy, cost-effective bicycle frame with improved geometrical control, reducing production time and material waste while maintaining structural integrity.
Implementation Method 1
arranging an expandable support; coating at least part of said expandable support with at least one layer of material pre-impregnated with a non-cured resin
Implementation Method 2
making said resin cure; joining at least one first and one second tube parts by a joint element made of a composite material comprising a cured resin
Data Source
Figure 1~2
Figure 3
Figure 4~5
AI summary
Method of manufacturing at least part, of a frame (1) of a bicycle, wherein the frame (1) comprises tube parts (2, 3) joined one to another, comprising the step of joining at least one first and one second tube parts (2, 3) by a joint element (5) made of a composite material comprising a cured resin. According to the invention, the following steps are provided of: inserting at least past of said joint element (5) when the resin is not cured, inside at least one end portion (2.1, 3.1) of each tube parts (2, 3). making said resin cure. The invention further provides the possibility of carrying out the afore said steps contemporaneously for all the joint elements provided in the frame. Object of the invention is also a device for manufacturing bicycle frames according to the afore said method, and a fram.e for bicycles manufactured through said method,