Carbon Frame Partitioning for Torsional Stiffness
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Carbon frames, due to their flexible nature, face challenges in maintaining torsional stiffness, especially under loads applied during pedaling in bicycles and other applications, where existing solutions have not effectively addressed this issue.
Innovation Solution
A manufacturing method involving the use of at least two forms combined with vinyl sheets, laminated with carbon prepregs of different orientations, and subjected to heat and wind, forming a partitioned carbon frame that enhances load distribution and torsional stiffness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If a carbon frame is used for its light weight and strength, then weight reduction is achieved, but torsional stiffness deteriorates due to the flexible characteristic of carbon material
Solution Approach 1:
The frame is divided into multiple separate carbon frame members (first carbon frame member, second carbon frame member, third carbon frame member) that are connected through bonding. This segmentation allows each member to be optimized for its specific structural role while collectively providing enhanced torsional stiffness compared to a single monolithic frame.
Solution Approach 2:
The invention uses carbon fiber reinforced plastic (CFRP) composite material for the frame members. The carbon fibers provide high strength and stiffness-to-weight ratio, while the resin matrix binds the fibers together. This composite structure maintains the light weight advantage of carbon material while achieving improved torsional stiffness through the multi-member configuration and bonding.
2Ease of manufacture
If carbon prepregs with single direction are used, then manufacturing is simplified, but load resistance in various directions deteriorates
Solution Approach 1:
Different carbon prepregs are assigned different fiber orientations (first direction, second direction, third direction) based on the specific structural requirements of each frame member and loading condition. This local optimization of fiber orientation ensures that each region of the frame has the appropriate strength characteristics for the loads it experiences, while still using straightforward unidirectional prepreg manufacturing processes.
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 effectively improves torsional stiffness by distributing loads and preventing frame twisting, allowing the carbon frame to be applied in demanding applications like bicycles and military equipment.
Implementation Method 1
injecting heat and wind into the vinyl sheets
Data Source
AI summary
Proposed are a carbon frame and a method of manufacturing the same capable of improving torsional stiffness. The method includes the steps of: (a) preparing at least two forms; (b) wrapping up the forms with vinyl sheets; (c) laminating carbon prepregs on the vinyl sheets; (d) combining the forms to put the combined forms in a mold; and (e) injecting heat and wind into the vinyl sheets.