Folded Bicycle Frame Using Hydroformed Sheet Metal
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Solution Overview
Problem
Conventional bicycle frame manufacturing is labor-intensive and costly due to the need for individual fabrication and assembly of tubular members, which results in misalignment issues and frequent points of failure, leading to increased costs and maintenance needs.
Innovation Solution
A lightweight bicycle frame is produced by stamping and folding a single sheet of metal using a hydroforming process, eliminating the need for welding and allowing for automated manufacturing, with pre-formed holes and bends for easy assembly of additional parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional tubular members and lugged frame joint fittings are individually fabricated and assembled through welding and brazing, then the frame can be constructed with multiple components, but the manufacturing process becomes slow, labor intensive, and costly
Solution Approach 1:
The patent merges multiple separate frame components (tubular members and lugged joints) into a single unitary sheet metal structure. This eliminates the need for individual fabrication and assembly of multiple parts, directly resolving the contradiction by simplifying the manufacturing process while simultaneously increasing production speed through stamping and folding operations.
Solution Approach 2:
The patent replaces the mechanical welding and brazing processes with a stamping and folding manufacturing system. This substitution eliminates labor-intensive manual operations and enables automated production, thereby improving ease of manufacture while dramatically increasing productivity through faster, automated sheet metal forming processes.
2Device complexity
If frame components are assembled in a welding jig, then the frame can be constructed with multiple parts, but considerable care must be taken to assure accurate alignment to prevent wheel tracking issues
Solution Approach 1:
By combining all frame components into a single unitary sheet metal structure, the patent eliminates the need for complex welding jigs and multi-component assembly processes. The inherent symmetry and single-piece construction automatically ensure precise alignment, eliminating wheel tracking issues without requiring complex alignment equipment or procedures.
3Ease of manufacture
If tubular members are welded or brazed at junctions, then the frame can be assembled from separate components, but these junctions become the most frequent points of failure susceptible to rust formation
Solution Approach 1:
The patent merges separate tubular members and joints into a continuous unitary sheet metal structure, eliminating welded or brazed junctions entirely. This single-piece construction removes the most frequent failure points, thereby improving reliability and rust resistance while maintaining ease of manufacture through stamping and folding processes.
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
This method reduces production time and costs, enhances frame alignment, and eliminates rust-related issues, resulting in a stronger, more durable, and cost-effective bicycle frame with reduced maintenance requirements.
Implementation Method 1
said single sheet of metal comprising bulges and curves along said sheet of metal, said bulges and curves resulting from a hydroforming process
Data Source
AI summary
A folded bicycle frame comprising a single and continuous sheet of metal is disclosed. The bicycle frame is formed by cutting the sheet of metal to form a boundary, hydroforming the sheet of metal to create a profile comprising indentations and protrusions along the sheet of metal, and then folding the molded sheet essentially along its axis of symmetry, such that the symmetrical parts of the sheet are positioned next to each other to form the frame with a hollow interior. Holes are precut in the frame so that other bicycle parts may be attached to the frame. The frame is produced without the need for any welding or connecting of individual parts. Thus, it is stronger than conventional bicycle frames which are weaker at such welded connections of their parts. A method for making the folded frame is also disclosed.