Bicycle Frame Cable Routing with Protected Head-Tube Connector
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Solution Overview
Problem
Retrofitting and protecting electrical components, particularly headlamps, on bicycles is complex and prone to damage due to the need for rerouting cables, which are often exposed and vulnerable during transport and assembly.
Innovation Solution
A bicycle frame with an integrated cable guide and cap on the head tube that houses an electrical connection, allowing easy attachment and detachment of components like headlamps, with a plug system that can be concealed when not in use, and includes cable guides to protect and secure cables.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If cables are routed outside the frame for easy access, then ease of operation is improved, but reliability deteriorates due to exposure to damage during transport and assembly
Solution Approach 1:
The electrical connection (plug) is integrated inside the cap that sits on the head tube, nesting the connector within the protective cap structure. This allows the cable to remain protected inside the frame while the cap provides an accessible interface for connecting electrical components like headlamps.
Solution Approach 2:
The cap acts as an intermediary element between the internal cable routing and the external electrical components. It provides a protected interface point on the head tube that allows cable connection without exposing the cable itself to external damage risks.
2Reliability
If cables are routed inside the frame for protection, then reliability is improved, but device complexity increases due to integrated cable guides and cap structures
Solution Approach 1:
The cap serves multiple functions simultaneously: it protects the upper bearing from elements, provides structural support on the head tube, and houses the electrical connection for cable access. This multi-functionality reduces the need for separate dedicated cable routing structures.
Solution Approach 2:
The electrical connection system is merged with the existing cap structure that is already part of the headset assembly. By integrating the plug into the cap rather than creating a separate cable management component, the overall device complexity is minimized while maintaining cable protection.
3Ease of manufacture
If electrical connections are integrated into the cap for compactness, then ease of manufacture is improved, but adaptability decreases for different electrical components
Solution Approach 1:
The plug integrated into the cap uses a standard connector design that can be replicated and matched by complementary plugs on different electrical components (headlamps, lights, etc.). This standardized interface design maintains adaptability across various components while simplifying the manufacturing process.
Solution Approach 2:
The electrical connection (plug) is pre-integrated into the cap during cap manufacturing, rather than being assembled separately during bicycle assembly. This preliminary action simplifies the overall assembly process while the standardized plug design maintains compatibility with various electrical components.
Data Source
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AI summary
The disclosure concerns a bicycle frame with integrated cable routing. At least one electrical connection is located in a cap that extends around the steerer tube and sits on the head tube.