Cycle Frame Core-and-Shell Assembly for Lightweight Strength
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current cycle frames and forks face challenges in achieving a balance between mechanical properties and weight, while also requiring high manufacturing costs and complex assembly processes, with limited design freedom and potential for excessive weight or insufficient strength.
Innovation Solution
A cycle frame or fork part comprising a core and two shells, where the shells are fixed to opposite lateral sides of the core without direct attachment to each other, allowing for enhanced design freedom and weight optimization through the use of different materials and reduced attachment surfaces, with the core designed to efficiently transfer mechanical constraints and potentially incorporate additional components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If welded metal tubes or composite tubes are used to assemble cycle frames, then mechanical strength can be achieved, but manufacturing complexity and labor costs increase due to welding, gluing, and finishing operations
Solution Approach 1:
The frame is divided into two separate half-shells that are molded independently and then joined together through interlocking features, eliminating the need for welding or gluing operations while maintaining structural integrity
Solution Approach 2:
The two half-shells are designed with complementary joining features that merge them into a unified structure through simple mechanical attachment, combining the benefits of separate molding with the appearance of a single-piece construction
2Device complexity
If a one-piece molded thermoplastic frame is used, then assembly complexity is reduced, but weight increases due to required wall thickness for strength
Solution Approach 1:
The frame is segmented into two thin-walled half-shells that can be molded with reduced wall thickness, and the combined structure achieves the required strength through the interlocking design rather than relying on thick walls
Solution Approach 2:
The two half-shells are designed to work together as a composite structure, where the combination of thin-walled components creates a stronger overall frame than a single thick-walled component would provide
3Strength
If two stamped metal shells are welded together at the periphery, then mechanical strength can be achieved, but finishing operations and specialized labor are required
Solution Approach 1:
The frame is divided into two separately molded half-shells with integrated joining features, eliminating the need for peripheral welding operations and associated finishing work
Solution Approach 2:
The joining features act as intermediaries between the two half-shells, providing a simple mechanical connection that replaces complex welding operations and reduces manufacturing steps
Data Source
AI summary
The present disclosure proposes a part of a cycle frame, such as a bicycle frame for example, and also a part of a cycle fork. The part of the cycle frame or of the cycle fork comprises a core (10) and at least two shells (11, 12) that surround the core and are fixed to the core without being fixed directly to each other.The present disclosure also relates to a method to assemble a cycle frame or a part of a cycle frame or a cycle fork or a part of a cycle fork.