Carbon Bicycle Saddle Leaf Spring for Wing Flex Comfort
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Solution Overview
Problem
Carbon fiber bicycle saddles are uncomfortable due to high stiffness, limiting design freedom and reducing the downward flex of the seat wings, which is crucial for ergonomic comfort during pedaling.
Innovation Solution
A saddle design featuring a seamless transition of the seat surface into a curved leaf spring, made of carbon fiber, which integrates with the struts, eliminating joints and allowing the wings to bend sideways for improved elasticity and comfort.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If carbon fiber is used for the saddle, then weight is reduced and strength is improved, but stiffness increases making the saddle uncomfortable
Solution Approach 1:
The saddle is divided into multiple carbon fiber layers with different orientations (0°, 45°, 90°) to create zones with different stiffness characteristics. The central area uses layers configured for flexibility while side areas use layers for support, allowing the saddle to be both lightweight and comfortable.
Solution Approach 2:
Different regions of the saddle have different structural properties - the central seat area is designed with more flexible carbon fiber layering to allow downward flex and comfort, while the side areas and nose have stiffer construction for support and durability.
2Ease of operation
If a curved leaf spring is used to support the seat surface, then comfort is improved, but manufacturing complexity increases due to overlapping carbon fiber layers
Solution Approach 1:
The curved leaf spring structure is integrated directly into the carbon fiber saddle shell by incorporating it into the same molding process. This merges the suspension function with the structural shell, eliminating separate components and overlapping layer issues while maintaining comfort.
Solution Approach 2:
The leaf spring is constructed using carbon fiber composite material with specific layer orientations that provide both the required flexibility for comfort and structural integrity, allowing it to be manufactured as part of the monolithic carbon saddle.
3Device complexity
If the seat surface transitions seamlessly into the leaf spring, then design freedom is improved and weight is reduced, but manufacturing precision requirements increase
Solution Approach 1:
The seamless transition between seat surface and leaf spring is achieved by pre-configuring the carbon fiber layers during mold preparation with precise orientation and positioning. This preliminary setup ensures that when the resin is injected and cured, the continuous transition is achieved without requiring post-manufacturing adjustments.
Solution Approach 2:
The manufacturing process uses controlled changes in carbon fiber layer orientation parameters and resin injection parameters to achieve the seamless transition. By precisely controlling these parameters during molding, the design freedom is realized while maintaining manufacturability.
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 design enhances ergonomic comfort by allowing the seat wings to deflect under load, reducing stiffness and weight while maintaining aesthetic appeal and structural integrity.
Implementation Method 1
the curved leaf spring connects to the seat, there is a section where two layers of carbon fiber lie on top of each other. This results in more complex manufacturing and stiffens the area where the seat rests on the leaf spring
Data Source
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AI summary
The invention relates to a saddle for a bicycle, the saddle comprising a saddle nose which merges into a seat surface via a transition region. The saddle also comprises two struts for attachment to a seat post head. The saddle nose, transition area, seat surface and struts are made of carbon. The nose of the saddle and one rear end of the seat surface each merge with the struts via a curved carbon leaf spring.