Abstract
A frame unit for a two-wheeled vehicle may comprise a main frame. The main frame may be formed by a first partial shell and a second partial shell that is joined to the first partial shell. The first partial shell and the second partial shell may be produced from a material comprising steel. The main frame may further comprise an upper tube, a lower tube, a seat tube, and/or a head tube. A rear section may be joined to the main frame and may include a chain stay and/or a seat stay. Further, each of the first and second partial shells may form a lateral half of the main frame, and the first and second partial shells may have a C-shaped cross section. The frame unit avoids the disadvantages of the prior art and offers a high degree of design freedom.
Claims
1.-17. (canceled)
18. A frame unit for a two-wheeled vehicle, the frame unit comprising a main frame that comprises a first partial shell and a second partial shell joined to the first partial shell, wherein the first and second partial shells are comprised of steel.
19. The frame unit of claim 18 wherein the main frame comprises at least one of an upper tube, a lower tube, a seat tube, or a head tube.
20. The frame unit of claim 18 wherein at least one of the first partial shell or the second partial shell is deep drawn.
21. The frame unit of claim 18 wherein a thermal weld joins the first partial shell and the second partial shell.
22. The frame unit of claim 21 wherein the first and second partial shells are joined together at least for a portion substantially along a primary loading direction.
23. The frame unit of claim 18 comprising a cable conduit that extends at least for a portion in the main frame between the first partial shell and the second partial shell.
24. The frame unit of claim 18 comprising a rear section that is connected to the main frame, wherein the rear section comprises at least one of a chain stay or a seat stay.
25. The frame unit of claim 18 comprising at least one of a bearing bushing, a head tube, a seatpost, a seat clamp, or a bottom bracket housing.
26. The frame unit of claim 18 wherein the first and second partial shells comprise at least one of a high-strength steel or a steel composite material.
27. The frame unit of claim 18 comprising a drive unit or a portion thereof and/or an energy accumulator or a tank therefor disposed between the first partial shell and the second partial shell in the main frame.
28. The frame unit of claim 18 wherein each of the first and second partial shells forms a lateral half of the main frame, wherein the first and second partial shells have a C-shaped cross section.
29. A method for producing a frame unit comprising a main frame for a two-wheeled vehicle, the method comprising: providing a first partial shell and a second partial shell, wherein the first and second partial shells comprise steel; and joining the first partial shell and the second partial shell to form the main frame.
30. The method of claim 29 wherein providing the first and second partial shells comprises deep drawing at least one of the first partial shell or the second partial shell.
31. The method of claim 29 comprising: positioning the first partial shell; and positioning on the first partial shell at least one of a bearing bushing, a head tube, a seatpost, a seat clamp, or a bottom bracket housing.
32. The method of claim 29 comprising: positioning stays for a rear section of the frame unit; connecting the stays by a connection element; and positioning the stays on the first partial shell.
33. The method of claim 32 comprising adapting the stays by way of chip removal.
34. The method of claim 29 comprising integrating a cable conduit for at least a portion in the frame unit.
35. The method of claim 29 wherein the joining of the first partial shell and the second partial shell comprises thermally welding the first partial shell to the second partial shell.
36. The method of claim 29 wherein the joining of the first partial shell and the second partial shell comprises laser welding the first partial shell to the second partial shell.
37. The method of claim 29 wherein the joining of the first partial shell and the second partial shell comprises laser hybrid welding the first partial shell to the second partial shell.
Description
[0041] The invention shall be explained in more detail hereafter with the aid of exemplary embodiments in connection with the drawing. The drawing shows in:
[0042] FIGS. 1-4 perspective views to illustrate an exemplary embodiment of a method for the production of a first exemplary embodiment of a frame unit according to the invention at various moments in time;
[0043] FIG. 5 a perspective view of the first exemplary embodiment of a frame unit according to the invention;
[0044] FIG. 6 an enlarged, see-through view of the frame unit in the area of the bottom bracket housing;
[0045] FIG. 7a,b perspective views of a second exemplary embodiment of a frame unit according to the invention;
[0046] FIG. 8a-d enlarged views of the main frame in the region of the head tube of the exemplary embodiment of FIG. 7; and
[0047] FIG. 9a-c various views of a third exemplary embodiment of a frame unit according to the invention.
[0048] FIGS. 1 to 4 show, first of all, perspective views to illustrate an exemplary embodiment of a method for production of a first exemplary embodiment of a frame unit 1 according to the invention, as is represented in FIG. 5, at different moments in time. The frame unit 1 in this example is a bicycle frame and consists substantially of a main frame 2 and a rear section 4. The substantially triangular or trapezoidal main frame 2 comprises a head tube 21, a seat tube 22, an upper tube 23 and a lower tube 24 (see FIG. 5).
[0049] FIG. 1a now shows first of all a perspective view of part of the rear section 4 for the frame unit 1 of FIG. 5. First of all, two stays are positioned, in this case two chain stays 6a, 6b, and connected by a folded piece 8. The chain stays 6a, 6b are each formed as closed hollow profiles, for example being made from folded pieces or joined half-shells. The chain stays 6a, 6b each comprise a recess 10a, 10b to accommodate the rear axle. The tolerances for the installation of the rear axle can be adjusted precisely. Furthermore, there is already integrated into the chain stay 6a a cable conduit 12 for the shifting cable, which runs inside the chain stay 6a, yet is represented for illustrative purposes.
[0050] FIG. 1b shows the portion of the rear section 4 from FIG. 1a, wherein now a bottom bracket housing 14 has additionally been arranged on the chain stays 6a, 6b and the folded piece 8. Owing to the separate design of the bottom bracket housing 14, the tolerance for the bottom bracket can be adjusted precisely.
[0051] An adapting, such as a further milling, of the chain stays 6a, 6b, may now optionally be carried out, if required.
[0052] FIG. 2 now shows a perspective view of a first partial shell 16a of the main frame 2 of the frame unit 1. The first partial shell 16a is designed in this case as a right half-shell and has a substantially C-shaped cross section. The first partial shell 16a has been made from steel plate by deep drawing. The first partial shell 16a has been placed in a fixture (not shown). This enables an exact positioning of add-on parts and the subassembly from FIG. 1.
[0053] As add-on parts, two bearing bushings 18 for the headset (not shown), a seat clamp 19 and the subassembly from FIG. 1 comprising the bottom bracket housing 14, the chain stays 6a, 6b and the folded piece 8 have been positioned and arranged on the partial shell 16a. Basically, however, individual elements can also be formed integrally with the partial shell 16a. Owing to the add-on parts 14, 18, 19, narrow tolerances can be set.
[0054] FIG. 3 shows a perspective view of the first partial shell 16a from FIG. 2, but now cable conduits 12, 30 have been placed additionally into the first partial shell 16a. The cable conduit 12 for the shifting cable runs substantially along the (as yet absent) lower tube 24 and the cable conduit 30 for the brake cable runs substantially along the (as yet absent) upper tube 23.
[0055] FIG. 4 now shows a perspective view of the arrangement from FIG. 3, wherein a second partial shell 16b has been positioned on the first partial shell 16a and joined to it. The second partial shell 16b is designed as a left half-shell and is substantially the mirror image of the first partial shell 16a. The first partial shell 16a and the second partial shell 16b for example have been joined together by means of laser welding or laser hybrid welding along the weld seams 17. In this way, a low degree of thermal warpage has occurred after the welding, resulting in a good dimensional accuracy of the frame unit and an accordingly small amount of additional work. As a result, a more attractive appearance can be achieved as compared to traditional welding methods.
[0056] The first partial shell 16a and the second partial shell 16b are joined together at least for a portion substantially along the main loading direction. As a result, the weld seams 17 are positioned in a load-oriented manner.
[0057] FIG. 5 now shows a perspective view of the first exemplary embodiment of the frame unit 1. As already discussed, the frame unit 1 is composed basically of a main frame 2 and a rear section 4. The main frame 2 has been formed by the joining of the first partial shell 16a and the second partial shell 16b. The main frame 2 is substantially triangular or trapezoidal and comprises a head tube 21, a seat tube 22, an upper tube 23 and a lower tube 24. The head tube 21 and the seatpost 25 are formed integrally with the main frame. The rear section 4 has been further supplemented with two additional stays, in this case seat stays 32a, 32b, each of which runs from the upper part of the seat tube 22 to the corresponding ends of the chain stays 6a, 6b. The seat stays are likewise joined together by a connection element 34. Owing to the seat stays 32a, 32b being designed to be separate from the main frame 2, they can be adapted individually. For example, different cross sections are possible for the seat stays 32a, 32b, such as round or oval cross sections. Oval cross sections favor an aerodynamic design.
[0058] Another preferred embodiment, not represented here, makes provision for first connecting together the seat stays, the chain stays and optionally the bottom bracket housing and then attaching them as a unit to the partial shells.
[0059] FIG. 6 shows an enlarged, see-through view of the frame unit 1 in the area of the bottom bracket housing 14. Owing to the separate construction of main frame 2, bottom bracket housing 14 and rear section 4 in the area of the bottom bracket, this node point can be designed to be especially rigid. This would only be possible in the case of a single-piece construction by means of reinforcing sheets. The encasing of the bottom bracket housing 14 by the half-shells 16a, 16b likewise favors the stability and optical appearance. Furthermore, the construction so as to be separate from the main frame 2 makes it possible to design the profiles of the chain stays 6a, 6b and the seat stays 32a, 32b as closed profiles.
[0060] FIG. 7a,b show two perspective views of a second exemplary embodiment of a frame unit 1 according to the invention, distinguished inter alia by a different main frame 2 than that of the frame unit 1.
[0061] FIG. 8a-d show enlarged views of the main frame 2 in the area of the head tube of the exemplary embodiment from FIG. 7. In contrast to the frame unit 1, rather than bearing bushings 18, the entire head tube 21 has been designed as an add-on part. This enables an extremely rigid head tube to be produced. However, the main frame 2 encloses the head tube 21. FIG. 8a shows the first partial shell 16a, FIG. 8b shows in addition the head tube 21, FIG. 8c shows furthermore in addition the second partial shell 16b in perspective view. FIG. 8d is a see-through view of FIG. 8c.
[0062] In other respects reference is made to the frame unit 1.
[0063] FIG. 9a-c show different views of a third exemplary embodiment of a frame unit 1 according to the invention. The frame unit 1 is similar to the frame unit 1. Accordingly, one may refer to the description of the frame unit 1. However, the seatpost 25 is not formed integrally with the main frame 2, but instead designed as a separate add-on part. This enables a rigid design of the seatpost. FIG. 9a, c shows the position of the seatpost 25 before the joining of the first partial shell 16a to the second partial shell 16b.
