E-Bike Frame Cable Routing for Protected Internal Integration
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Solution Overview
Problem
Existing electric bicycle frames fail to provide a seamless integration of electrical components and their connections, leading to exposure to environmental influences and inconvenience in assembly and use.
Innovation Solution
The bicycle frame integrates chambers within the seat and head tubes as cable guides, allowing for protected routing of electrical cables, including a plug system for easy installation and replacement, and positions charging ports and displays inconspicuously for user convenience.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If electrical cables are routed openly from power supply unit to display and lights, then assembly and cable installation is simple, but electrical components and cables are exposed to environmental influences
Solution Approach 1:
The patent implements cable routing channels that are nested within the frame tubes themselves. The down tube and seat tube contain internal passages that house the electrical cables, protecting them from environmental exposure while maintaining integrated assembly. The cables are routed through these nested channels from the power supply unit mounted in the down tube to the display and lights.
2Object-affected harmful factors
If power supply unit is integrated into down tube with side opening closed by cover, then power supply unit is protected and inconspicuous, but charging access requires removing cover
Solution Approach 1:
The down tube is segmented into functional zones: an upper sealed chamber containing the power supply unit for protection, and a lower accessible region with integrated charging ports. The sealing element creates a clear separation between the protected internal space and the external charging interface, allowing the power supply to remain concealed while charging remains easily accessible.
3Device complexity
If charging port is located near power supply unit in down tube, then cable routing is simplified, but charging port becomes difficult to access without bending over
Solution Approach 1:
The charging port is repositioned from the traditional horizontal location near the power supply unit to a vertical arrangement on the lower part of the down tube. This dimensional change allows the charging interface to be accessed from below, eliminating the need to bend over while maintaining simplified cable routing through the frame structure.
4Ease of operation
If display is mounted on handlebars or stem, then display is easily visible and accessible, but cable routing to display becomes more complex
Solution Approach 1:
The frame tubes are designed with universal multi-functional cable routing channels that serve multiple purposes: they protect cables from environmental exposure, provide structural integration, and guide cables from the power supply unit to various components including the display mounted on handlebars or stem. This universal cable management system simplifies routing to elevated display positions.
Data Source
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AI summary
The invention relates to a bicycle frame for electric bicycles, with several frame struts forming at least a down tube, a seat tube 20 and a head tube of the bicycle frame, with a holding device for an electric motor, with at least one receptacle for a power supply unit for the electric motor, wherein the seat tube has an outer circumference 22 and an insertion opening 21 for a seat post, and wherein at least one frame strut has an integrated chamber as a cable guide channel.In order to create a bicycle frame that is easy to assemble and use and consistently integrates all necessary electrical components, the invention provides that the seat tube 20 has a chamber 25 closed at the outer circumference 22 as a cable guide channel for at least one electrical cable, wherein the cable guide channel is provided with an open passage 26 extending along the insertion space for the seat post to the insertion opening 21 for the seat post (Fig. 2).