E-Bike Frame Tube Reinforcement Around Battery Cutouts
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The integration of an electric energy storage device into a bicycle frame tube requires structurally weakening cut-outs, leading to increased manufacturing costs and complexity due to the need for additional reinforcement, which existing methods like welding individual ribs are costly and time-consuming.
Innovation Solution
A modular reinforcement device with axially extending first and second reinforcement elements, angled at least 45°, which can be installed separately and connected to the frame tube via screw connections or welding, providing structural stiffness without continuous welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If individual reinforcing ribs are welded to the frame tube to provide structural stiffness, then frame stiffness is improved, but manufacturing cost and complexity increase significantly
Solution Approach 1:
The reinforcement elements are merged with the frame tube through integral forming, where the reinforcement structure is created as a single piece with the tube rather than assembling separate components. This eliminates the need for welding individual ribs and reduces manufacturing complexity while maintaining structural stiffness.
Solution Approach 2:
The reinforcement structure is segmented into discrete reinforcement elements that can be individually formed and positioned within the tube, rather than requiring continuous welding of complex rib structures. This segmentation allows for simpler manufacturing processes while achieving the required structural reinforcement.
2Strength
If individual reinforcing ribs are welded to the frame tube to provide structural stiffness, then frame stiffness is improved, but manufacturing time increases
Solution Approach 1:
The reinforcement elements are integrated with the frame tube through integral forming processes, allowing both components to be manufactured simultaneously as a single piece. This eliminates sequential welding operations and significantly reduces manufacturing time while maintaining the required structural stiffness.
Solution Approach 2:
The reinforcement structure is pre-formed as integral parts during the tube manufacturing process rather than being added later through welding. This preliminary action eliminates subsequent welding steps and accelerates production while ensuring consistent structural quality.
3Ease of operation
If a cut-out is provided in the frame tube to accommodate the energy storage device, then accessibility for charging is improved, but structural integrity deteriorates
Solution Approach 1:
The frame tube is designed with locally optimized reinforcement elements positioned specifically at the cut-out area and along the tube length. This local quality enhancement provides targeted structural support where needed, maintaining overall structural integrity while preserving the cut-out for energy storage device accessibility.
Solution Approach 2:
The reinforcement structure is segmented into discrete elements that can be strategically positioned to reinforce the cut-out area without requiring continuous reinforcement throughout the entire tube. This segmented approach maintains structural integrity at critical locations while preserving accessibility features.
Data Source
AI summary
A reinforcement device for reinforcing an electric bicycle frame at least in a region of a tube cutout of a bicycle frame tube which accommodates an energy storage. The reinforcement device includes a first reinforcement element which extends axially in the bicycle frame tube and/or extends at a certain angle to the bicycle frame tube, and at least one second reinforcement element which extends axially in the bicycle frame tube. The reinforcement device is installed in the bicycle frame tube.