Thermoplastic Composite Bicycle Frame Shell Assembly
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Solution Overview
Problem
Conventional manufacturing methods for thermoplastic composite bicycle frames involve complex operational steps and cannot produce a substantially complete frame directly, leading to stress concentration and defects at curved parts.
Innovation Solution
A manufacturing method that involves forming thermoplastic composite laminates into multiple shells with aligned straight and curved segments, assembling them with overlapping straight edges and butt-jointed curved edges, and connecting them through compression molding to form a complete frame, while using a supporting unit and reinforcement material to enhance structural strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the bicycle frame is separated into several units at curved parts to solve stress concentration, then stress concentration is reduced, but the operational steps become complicated and a substantially complete bicycle frame component cannot be made directly
Solution Approach 1:
The invention divides the bicycle frame into multiple shells (first shell, second shell, third shell) that can be formed separately through compression molding and then assembled together. This segmentation allows each shell to be optimized independently while maintaining the ability to form a complete frame through assembly, resolving the contradiction between reducing stress concentration and simplifying operational steps.
Solution Approach 2:
The invention merges multiple separately formed shells into a substantially complete bicycle frame component through assembly and fusion processes. By combining the first shell (with first curved part), second shell (with second curved part), and third shell (with third curved part), the invention achieves both stress concentration reduction at curved parts and formation of a complete frame structure.
2Ease of manufacture
If multiple shells are assembled with overlapped edges to connect parts, then assembly is simplified, but stress concentration and defects occur at curved parts
Solution Approach 1:
The invention applies different connection methods to different parts of the frame: straight connecting edges use overlapping connection for ease of assembly, while curved connecting edges use butt joint connection to reduce stress concentration. This local differentiation of connection quality resolves the contradiction between assembly simplicity and stress reduction at curved parts.
Solution Approach 2:
Instead of using the conventional overlapping connection method for all edges, the invention inverts the approach at curved parts by using butt joint connection where the curved connecting edges are placed substantially adjacent to each other without overlap. This inversion eliminates stress concentration and defects at curved parts while maintaining assembly feasibility through the hybrid connection approach.
3Productivity
If conventional compression molding is used to combine multiple shells, then mass production capability is improved, but the process cannot produce a substantially complete bicycle frame component directly
Solution Approach 1:
The invention performs preliminary formation of multiple shells with predetermined connecting edges through compression molding before final assembly. The shells are pre-formed with straight connecting edges and curved connecting edges that are designed for specific connection methods, enabling efficient subsequent assembly while maintaining mass production capability through the initial compression molding step.
Solution Approach 2:
The invention nests multiple shells within each other during the assembly process, where the first shell, second shell, and third shell are positioned and fused together in a sequential manner to form a substantially complete bicycle frame component. This nesting approach streamlines the assembly process while maintaining the ability to produce complete frames efficiently.
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 simplifies the process, reduces stress concentration, and improves the quality of the frame by eliminating defects such as mold clamping and wrinkling, enabling a complete and structurally sound bicycle frame with reduced assembly steps.
Implementation Method 1
turning thermoplastic composite laminates into multiple shells by compression molding
Implementation Method 2
through compression molding, turning the overlapped straight connecting edges and the butt jointed curved connecting edges of the multiple shells into multiple fusion areas by heating and compressing
Implementation Method 3
by heating and compressing so as to connect the multiple shells as a bicycle frame component
Implementation Method 4
by heating and compressing so as to connect the multiple shells as a bicycle frame component
Data Source
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AI summary
The method comprises a shell forming step: turning thermoplastic composite laminates (10) into shells (20A, 20B) by compression molding, wherein each shell (20A, 20B) has a cavity (21A, 21B), at least one straight segment (22A, 22B) and at least one curved segment (23A, 23B) connected therewith; a shell assembling step: assembling the shells (20A, 20B) to make straight connecting edges (221A, 221B) of the straight segments (22A, 22B) overlapped with one another and to make curved connecting edges (231A, 231B) of the curved segments (23A, 23B) butt jointed with one another; and a hot pressing step: turning the straight connecting edges (221A, 221B) and the curved connecting edges (231A, 231B) into fusion areas by heating and compressing so as to connect the shells (20A, 20B) as a bicycle frame component (20).