Integrated Carbon Fiber Track Bicycle Frames for Rigidity and Aerodynamics
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Solution Overview
Problem
Existing track bicycles suffer from carbon fiber discontinuity, which affects rigidity and strength, leading to poor aerodynamic performance and increased air resistance due to complex assembly methods and inadequate consideration of cross-sectional shape and weight distribution.
Innovation Solution
A carbon fiber integrated frame with optimized fiber layer distribution and asymmetric tube designs, combined with streamlined structures and integrated molding technology, ensures continuous carbon fiber distribution and improved strength and aerodynamics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If multi-stage assembly method is used for frame construction, then ease of manufacture is improved, but carbon fiber discontinuity occurs reducing rigidity and strength
Solution Approach 1:
The patent merges multiple frame tubes into a single integrated carbon fiber structure, eliminating the need for multi-stage assembly. The head tube, upper tube, lower tube, seat tube, and other components are formed as one continuous piece through integrated molding, ensuring carbon fiber continuity throughout the frame structure and eliminating weak points at connection joints.
Solution Approach 2:
The patent segments the carbon fiber reinforcement into different directional layers within the integrated frame structure. By arranging carbon fiber bundles in specific orientations (longitudinal, transverse, and diagonal directions) at different locations, the design achieves both structural integrity and optimized mechanical properties without requiring assembly joints.
2Adaptability or versatility
If complex assembly method is used, then adaptability is improved, but connection points increase reducing overall closure degree and stability
Solution Approach 1:
The patent combines multiple frame components into a single monolithic carbon fiber structure, eliminating all connection points and joints. This integrated design maintains overall closure degree and aerodynamic stability while providing adaptability through optimized fiber orientation and structural geometry rather than through assembly configurations.
3Ease of manufacture
If insufficient consideration of cross-sectional shape and tube shape is given, then ease of manufacture is improved, but aerodynamic performance is not fully utilized
Solution Approach 1:
The patent applies different cross-sectional shapes to different frame tubes based on their specific aerodynamic requirements and structural functions. The head tube, upper tube, lower tube, and seat tube each have optimized cross-sectional geometries (circular, elliptical, or airfoil-shaped) tailored to their local aerodynamic environment, while all are manufactured as one integrated piece through molded carbon fiber composite technology.
4Ease of manufacture
If multi-stage assembly method is used, then ease of manufacture is improved, but rigidity is reduced due to carbon fiber discontinuity
Solution Approach 1:
The patent merges all frame tubes into a single continuous carbon fiber structure, eliminating discontinuities at assembly joints. The integrated molding process ensures uninterrupted carbon fiber reinforcement throughout the entire frame, maximizing rigidity and strength while maintaining manufacturing feasibility through automated fiber placement and molding techniques.
Data Source
AI summary
Provide are a carbon fiber field bicycle and a manufacturing method thereof. The frame includes a frame formed by the integrated solidification of carbon fiber. The frame includes a front triangular structure composed of an upper tube, a lower tube, and a seat tube; and a rear triangular structure composed of a seat branch tube, a transmission branch tube, and a seat tube. The fiber layers corresponding to the tube fittings forming the front triangular structure is distributed along the axial direction of the corresponding tube fittings. In view of the current problem of poor strength and rigidity of track bicycles, a carbon fiber integrated frame is adopted as the main structure, and the fiber layer distribution of each tube component and key node position of the frame is optimized to ensure continuous distribution of carbon fibers and improve the strength of track bicycles.