Composite Bicycle Frame with Embedded Electrical Wiring
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Solution Overview
Problem
Existing bicycle frames with composite materials face challenges in integrating electronic gear-shifting and braking systems, as the configuration of cables and wires adds complexity and cost to the assembly process, and existing methods do not efficiently hide unsightly cables while maintaining structural integrity.
Innovation Solution
A composite bicycle frame with a composite layup structure that embeds electric wires and cables within the material, allowing them to be integrally formed and concealed, reducing assembly time and cost, and enabling seamless integration with electronic components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If cables are passed inside hollow frame tubing, then aesthetic appearance is improved by hiding cables, but assembly complexity increases due to additional assembly steps required to feed cables through tubes
Solution Approach 1:
The patent merges the cable routing function with the frame structure itself by embedding cables within the composite material layers during manufacturing. This eliminates the need for separate cable feeding steps through hollow tubes, as the cables are integrated into the frame's construction process, thereby reducing assembly complexity while maintaining aesthetic appearance.
Solution Approach 2:
The cables are placed within the composite material layers during the frame manufacturing process itself, before the frame is completed. This preliminary action incorporates cable routing into the primary manufacturing step, eliminating subsequent cable installation steps and reducing overall assembly complexity while achieving hidden cable aesthetic.
2Adaptability or versatility
If electronic components are integrated into composite frames, then functionality is improved, but manufacturing complexity increases due to integration requirements
Solution Approach 1:
The patent combines electronic component integration with the composite frame manufacturing process by embedding wires and cables within the composite material layers. This merging of functions allows electronic systems to be integrated directly during frame construction, eliminating separate integration steps and reducing manufacturing complexity despite the added functionality.
Solution Approach 2:
The composite frame structure serves multiple functions simultaneously: it provides structural support, aesthetic appearance, and integrated electrical connectivity for electronic components. By making the frame multi-functional through embedded wiring, the patent achieves electronic system integration without proportionally increasing manufacturing complexity, as the same manufacturing process accomplishes both structural and electrical functions.
3Ease of manufacture
If cables run along the outside of frame tubing, then assembly simplicity is maintained, but aesthetic appearance deteriorates due to visible cables
Solution Approach 1:
The patent merges cable routing with the frame's structural material by embedding cables within the composite layers. This approach maintains assembly simplicity because cables are incorporated during the single manufacturing process rather than requiring separate routing steps, while simultaneously achieving hidden cable aesthetic appearance.
4Shape
If hollow tubes are used for cable routing, then cable concealment is achieved, but structural integrity may be compromised and manufacturing cost increases
Solution Approach 1:
The patent uses composite materials with embedded cables, where the cables are integrated within the composite material layers rather than requiring hollow tubes. This approach achieves cable concealment while maintaining structural integrity because the composite structure provides strength without requiring hollow cavities, and the embedded cables become part of the load-bearing composite structure.
Data Source
AI summary
A composite bicycle frame which comprises of a main frame including interconnected tubes and substantially composed of a composite material and having a composite layup structure. At least one electric wire electrically interconnects electrical components mounted to or in the frame. The at least one electric wire is embedded in the composite material structure forming the composite main frame. The electric wire has connectable conductive ends at each of the opposed ends thereof.