Thermoplastic Composite Bicycle Components with Honeycomb Core
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Solution Overview
Problem
The production of lightweight composite components for bicycles, such as frames, saddles, and shoes, is complex and time-consuming due to the lengthy baking processes and subsequent post-processing steps like grinding and polishing, which hinders efficient series production and shape variety.
Innovation Solution
A method involving a lightweight structure with a honeycomb core, pre-impregnated fiber composite mats, and thermoplastic impregnation, where the combination is pressed and shaped using heat to create a semi-finished product that can be deep-drawn and back-injected with thermoplastic to form complex shapes without requiring edge processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If fiber-reinforced composites are used for lightweight structures, then weight is reduced, but production time increases due to lengthy baking processes
Solution Approach 1:
The patent changes the material parameter from thermoset resin to thermoplastic resin, which fundamentally alters the processing behavior. Thermoplastic resins do not require lengthy baking/curing processes like thermosets, enabling faster production while maintaining the lightweight composite structure
Solution Approach 2:
The patent utilizes the phase transition properties of thermoplastic resins, which soften at elevated temperatures and solidify upon cooling. This allows the composite to be formed and shaped during the heating process without requiring extended curing time, thus reducing production time while achieving the desired lightweight structure
2Weight of moving object
If traditional composite manufacturing is used, then lightweight structures are achieved, but manufacturing complexity increases due to extensive post-processing steps
Solution Approach 1:
The patent incorporates the lightweight structure (honeycomb core) and reinforcement fibers into the composite panel during the initial forming process. This preliminary integration eliminates the need for separate post-processing steps to add these features, simplifying the overall manufacturing process while maintaining the lightweight design
Solution Approach 2:
The patent combines multiple functions and features into a single integrated composite panel manufacturing process. The lightweight honeycomb structure, fiber reinforcement, and thermoplastic matrix are formed together in one process, eliminating the need for separate post-processing operations and reducing manufacturing complexity
3Loss of time
If thermoplastic impregnation is used, then processing time is reduced, but bonding requirements become more specific
Solution Approach 1:
The patent specifies particular parameter ranges for the thermoplastic impregnation process, including temperature (above Tg but below decomposition temperature), pressure, and resin content. These controlled parameters ensure proper bonding while maintaining fast processing times, resolving the contradiction between speed and manufacturability
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 significantly reduces production time, allows for a wide range of shapes, and enhances mechanical stability, resulting in lightweight yet robust bicycle components with reduced weight and improved torsional stiffness.
Implementation Method 1
The pressing process takes place under the influence of heat, causing the impregnation to melt and bond the fiber composite mats and lightweight structure together
Implementation Method 2
To bond the fiber composite mats, the component only needs to be heated above Tg and then cooled to room temperature
Data Source
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Figure 3
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AI summary
The invention relates to a method for producing a component having a light-weight structure. According to the invention, impregnated fiber mats are applied to a light-weight structure that comprises hollow chambers.