Patent Application
20190367118
The invention is related to a two-tier structural frame for a three-wheeled cargo bike. The structural frame is intended to be the platform for the entire bike and is related to steering and suspension parts.
Cargo bikes have been around for decades in many parts of the world. The United States currently does not have an American cargo bike company that designs and manufactures a three-wheeled bike with the cargo in the front of the bike for the American market.
Cargo bikes exist in American factories for carrying tools. These are cargo “trikes” where the materials are carried in the back of the bike. Other cargo bikes in the United States are designed and constructed by hobbyist and do not take into consideration function, safety, and efficient or smooth travel.
These and other issues presented by current designs can be addressed with the present invention.
The present invention is designed to meet the needs of people living in cities in the United States, and around the world. One aspect of the invention is directed to a three-wheeled bike that is stable, safe, and easy to turn. Other considerations in the design and implementation of the invention are the economics and ease of production. The present invention can be mass-produced for consumers in North America, and beyond.
A majority of American cities sprawl out greater distances and are less compact than most cities around the world. An benefit of the present invention is that it can be used to travel long distances, at greater speeds than prior art designs, and still be narrow enough to fit in a one-way bike lane. The present invention can be used to travel comfortably over paved or unpaved surfaces while maintaining structural stability, in part because of the two-tiered design.
The frame of embodiments of the present invention can absorb and distribute forces during straight-line travel and while turning. The two-tiered frame allows the suspension system to operate correctly and offer the bike its functionality & durability qualities. The a-arms and kingpin of the invention enable the wheels to spin into the direction of a turn and not slip or skip sideways when traveling around a curve. The rod and plate steering mechanisms of the invention assure firm anchorage to the kingpin, which holds the axles and wheels/tires. The shocks on each side of the frame control vibratory motion and offer resistance in the form of unwanted bounce and keep the tires planted on the ground. The a-arms link both sides of the bike on the top and bottom of the frame rail. The a-arms can be a hinged suspension linkage. These elements can be any suitable shape. In some embodiments, the a-arms can be u-shaped and include two or more pinned connections at each end. The purpose of the a-arm is to link the kingpin the frame, the suspension and the axle that carries the wheel. A-arms interconnect the shocks to the top tube and the bottom tube of the frame. The lower a-arm connects the bottom of the shock at the piston mount, while the cleats for the to the fixed top shock mount are linked (directly or indirectly) to the top frame rail.
The design of the suspension, frame, and steering mechanism is based on their close relationship to one another, which was established by exploration of the Ackermann equation for use in a cargo bike. The present invention is believed to be the first front wheel design cargo bike with Ackermann steering and a suspension system.
In the Ackermann equation, the geometry is validated only when the wheels and axles are organized as radii of circles with a common central point in a turned position. The rear wheel of the present invention is fixed, while the front wheels are not fixed and can turn. From this fixed point (at the rear axle) a line is drawn. Then two lines are drawn from each of the front axles back to a central point from the rear axle. In a computer model, the equation is proven when all circles drawn can be traced to a common point. A successful “real world” result happens when the outside wheel is positioned at a greater angle (β) (i.e., between about 90° and about 180°, or in some embodiments between about 105° and about 120° than the angle for the inside wheel (α), while turning, with relation to Ackermann point as illustrated when the wheels are turning right as illustrated in
Angled wheel positioning and the incorporation of shocks create a system that works to keep the operator safely positioned on the vehicle and counter balance the forces going into a turn. In an embodiment of the present invention, the top and bottom a-arms on the cargo bike can be vertically offset between about 0.75 inches and about 1.5 inches, and in some embodiments about one inch, when viewed from the top down. This offset helps achieve a steep angle on the kingpin. The kingpin has at least one bolted attachment at the top center and the bottom center of each a-arm. The bottom of the kingpin is angled outward further toward the front of the bike than the top. This configuration provides faster steering with less effort required to steer the cargo bike. This relationship between the top and bottom a-arms works in the same manner as the head tube and fork to facilitate the steering of a standard two-wheel bicycle.
Further, this configuration and positioning works to provide a design that assist wheels/tires to angle from tire patch to top of tire and firmly, plant the wheels/tires on the road surface while cornering, thus allowing the bike to steer without having the tires skidding and slipping during the turn.
The arrangement of the suspension components and the sizing of each are dependent on the bike's overall frame width, as well as the kingpin on center-to-center width.
The two-tiered frame is an integral part of the success of this offset between the top and bottom a-arms. The bottom and top tubes are mathematically positioned to be spaced apart the height of the kingpin. A-arms are bolted to water-jet-cut plain-steel cleats, which are adhered to the bike with welds or other joining methods.
It is another aspect of the present invention to provide a two-tiered frame design having two levels of frame structure with one frame positioned over the other. The on-center locations (i.e. the location at about the middle of the a-arm in relation to the height oh the bike) of the top and bottom tubes are dictated by the length the kingpin. In some embodiments, center tubes connect the front and back of the bike. The two-tiered frame in the front extends to the seat post via the center top and bottom frame tubes where the rider is positioned. In one embodiment, angled vertical supports tie the top and bottom frames together. In another embodiment, each side only has one angled vertical support because the front of the frame is curved and the top tube curves down to interconnect with the bottom tube.
It is one aspect of the present invention to provide an aesthetically pleasing design. There are two aesthetic qualities of the frame design. First, the side supports in the front of the bike are the same angle as the seat post. Second, the look of the frame is carried from the front of the bike to the back of the bike for a homogeneous look.
Another aspect of the present invention is a platform that offers the user flexibility regarding the use of the platform. Specifically, the occupant basket is not required to be a permanent part of the overall structure, which means an occupant basket can be incorporated for people or items people may want to carry or the occupant basket can be removed entirely. The two-tiered frame provides the ability to manufacture the occupant basket from a variety of materials including, but not limited to, steel, aluminum, wood, titanium, other metal, composite, carbon fiber, or polycarbonate. The strength of the two-tiered frame allows for any configuration of basket to be fastened to the frame, without the need for the basket to be overdesigned. Thus, an occupant basket only needs to have enough strength for itself and its occupants. Additionally, the rest of the bike does not rely on the basket for strength. Thus, a basket can be a lighter weight material (e.g. composite, plastic, etc.).
Additionally, the two-tiered frame design can be used without the basket in a flatbed mode for carrying cargo. Thus, the frame itself can be used for transport as a flatbed with a sheathing over the frame. The frame can be covered in steel, aluminum, wood, titanium, or polycarbonate to take on the utility of a traditional flatbed truck. Accordingly, the user can carry cargo as high or heavy as he/she can safely maneuver.
One aspect of the invention is to provide a bike that is stable. This bike stability is accomplished by having a frame that is low to the ground and, therefore, has a low center of gravity. Additionally, the material of the bike frame can be steel (or other metal) where the overall weight is on the bottom of the bike.
It is another aspect of embodiments of the present invention to provide a frame with an improved rear triangle. The rear triangle interconnects the seat post to the rear wheel/tire. Thus, the seat post completes the rear triangle, which is capable of housing two types of tires. The bike according to embodiments of the present invention can have a street-oriented tire that is thin and smooth, much like a traditional road bike tire. Alternatively, the rear triangle can accommodate a mountain bike tire or snow tire, which is thicker and rougher than the street-oriented tire.
In some embodiments, the width of the rear triangle of the bike can accommodate a rear hub for an e-assist system (i.e. an electric motor to propel one or more wheels of the bike). Also, dropouts, one or more tabs, typically made of metal, on the drive side of the bike near where the rear wheel is anchored in the frame, are adjustable and remove any tension in the belt drive system. In order to add tension to the drive belt, an adjustable drop out allows the rear wheel to be slid or pivoted into place then fastened. By moving the wheel away from the crank set, chain tension is increased on the dropout by hand turning the tensioner.
It is another aspect of embodiments of the present invention to provide a bike with side-mounted suspension. An advantage of the two-tiered design is that the suspension is mounted on the side of the bike. The a-arm suspension can be attached (e.g. bolted) onto cleats that are attached to the top and bottom rails/tubes of the frame, which allows the frame to be lower to the ground and flatter in turns than prior art designs. This system is in stark contrast to the tilting or leaning cargo bike offerings from Butchers & Bikes (as described in WO2015067760) or Veleon systems. Additionally, the side mounted suspension keeps the frame lower to the ground, which keeps the occupants and cargo flatter and more stable throughout turns and curves. The side suspension also flattens the travel for the of center of bike relative to the height of the bike.
In one embodiment, on the bottom of the bike, located directly under the frame, is the steering mechanism, which is a proprietary design consisting of steel rods attached to stainless steel water-jet-cut parts.
In one embodiment, a method of assembly process is provided comprising: milling steel; placing the steel in a jig for a front of a bike; performing tack attachments; completing the attachment; removing the bike from the jig; milling and forming steel into a rear triangle for the bike; place the rear triangle in the jig; performing tack attachments on the rear triangle; incorporating drop outs; completing the attachments on the rear triangle; removing the rear triangle from the jig; placing the front of the bike in the jig; placing the back of the bike in a second jig; tack attaching a top tube and a bottom tube to the front and back of the bike; remove the bike from the jigs; and attaching the center structural tube to the bike. The order depicted in these steps can be altered without deviating from the invention. For example, the steps can be in reverse, or a section of the bike can be manufactured then joined to the remaining portions of the bike. The attachments can be by welding, gluing, brazing, soldering, and other fusion processes that create a sufficient amount of strength to permanently join the materials. In some embodiments, the attachment method can be welding.
In another embodiment, a method of assembling a cargo bike frame is provided comprising: placing steel tubes for a front of the bike onto a cutting bed of a laser cutter; cutting both ends of each steel tube, wherein the cut is a straight cut or a miter cut; bending each tube into a desired shape to form a top tube and a bottom tube; placing the shaped tubes onto a jig; placing internal sleeves on selected butt joints; performing tack attachments on joints & joined parts; completing the attachments; removing the bike from the jig; milling and forming steel into a rear triangle; placing the rear triangle in the jig; performing tack attachments on joints & joined parts; incorporating drop outs; completing the attachments; removing the rear triangle from the jig; placing the front of the bike and a back of the bike into the jig; tack attachments the top tube to the front and back of the bike; tack attachments the bottom tube to the front and back of the bike; removing the bike from the jig; attachments the center structural tube to the bike. The order depicted in these steps can be altered without deviating from the invention. For example, the steps can be in reverse, or a section of the bike can be manufactured then joined to the remaining portions of the bike. The attachments can be by welding, gluing, brazing, soldering, and other fusion processes that create a sufficient amount of strength to permanently join the materials. In some embodiments, the attachment method can be welding.
The phrases “at least one,” “one or more,” and “and/or,” as used herein, are open-ended expressions that are both conjunctive and disjunctive in operation. For example, each of the expressions “at least one of A, B and C,” “at least one of A, B, or C,” “one or more of A, B, and C,” “one or more of A, B, or C,” and “A, B, and/or C” means A alone, B alone, C alone, A and B together, A and C together, B and C together, or A, B, and C together.
Unless otherwise indicated, all numbers expressing quantities, dimensions, conditions, and so forth used in the specification and claims are to be understood as being modified in all instances by the term “about”.
The term “a” or “an” entity, as used herein, refers to one or more of that entity. As such, the terms “a” (or “an”), “one or more,” and “at least one” can be used interchangeably herein.
The use of “including,” “comprising,” or “having” and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. Accordingly, the terms “including,” “comprising,” or “having” and variations thereof can be used interchangeably herein.
It shall be understood that the term “means” as used herein shall be given its broadest possible interpretation in accordance with 35 U.S.C. Section 112(f). Accordingly, a claim incorporating the term “means” shall cover all structures, materials, or acts set forth herein, and all of the equivalents thereof. Further, the structures, materials, or acts and the equivalents thereof shall include all those described in the summary of the invention, brief description of the drawings, detailed description, abstract, and claims themselves.
These and other advantages will be apparent from the disclosure of the invention(s) contained herein. The above-described embodiments, objectives, and configurations are neither complete nor exhaustive. The Summary of the Invention is neither intended nor should it be construed as being representative of the full extent and scope of the present invention. Moreover, references made herein to “the present invention” or aspects thereof should be understood to mean certain embodiments of the present invention and should not necessarily be construed as limiting all embodiments to a particular description. The present invention is set forth in various levels of detail in the Summary of the Invention as well as in the attached drawings and the Detailed Description and no limitation as to the scope of the present invention is intended by either the inclusion or non-inclusion of elements, components, etc. in this Summary of the Invention. Additional aspects of the present invention will become more readily apparent from the Detailed Description, particularly when taken together with the drawings.
Those of skill in the art will recognize that the following description is merely illustrative of the principles of the invention, which may be applied in various ways to provide many different alternative embodiments. This description is made for illustrating the general principles of the teachings of this invention and is not meant to limit the inventive concepts disclosed herein.
The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate embodiments of the invention and together with the general description of the invention given above and the detailed description of the drawings given below, serve to explain the principles of the invention.
It should be understood that the drawings are not necessarily to scale, and various dimensions may be altered. In certain instances, details that are not necessary for an understanding of the invention or that render other details difficult to perceive may have been omitted. It should be understood, of course, that the invention is not necessarily limited to the particular embodiments illustrated herein.
Although the following text sets forth a detailed description of numerous different embodiments, it should be understood that the legal scope of the description is defined by the words of the claims set forth at the end of this disclosure. The detailed description is to be construed as exemplary only and does not describe every possible embodiment since describing every possible embodiment would be impractical, if not impossible. Numerous alternative embodiments could be implemented, using either current technology or technology developed after the filing date of this patent, which would still fall within the scope of the claims.
While various embodiments of the present invention have been described in detail, it is apparent that modifications and alterations of those embodiments will occur to those skilled in the art. However, it is to be expressly understood that such modifications and alterations are within the scope and spirit of the present invention, as set forth in the following claims. Further, the invention(s) described herein is capable of other embodiments and of being practiced or of being carried out in various ways. It is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting.
Some of the large diameter tubing 1, 2, 5 supports the cargo area 54. The top tubing 1 and bottom tubing 2 of the frame are interconnected (for example, welded in one embodiment) on one end to the steering column tube 3. On the front end of the bike frame, the top tubing 1 curves downward and interconnects to the bottom tubing 2. The tubing 56, 58 behind the steering column 3 terminate and are interconnected (for example, welded in one embodiment) to the seat post 52. In the embodiment shown, the tubing 56, 58 behind the steering column 3 are large diameter tubing. Both tubing 56, 58 can be the same diameter or can be different diameters. For example, the lower tubing 56 can have a larger diameter than the upper tubing 58.
The smaller diameter tubing 4 forms the rear triangle and is interconnected (for example, welded in one embodiment) to the seat post 52. There are multiple tubes 4 on the rear triangle, but only two are visible in this view. Each tube 4 can be the same diameter and thickness, or different diameters and thicknesses. The diameter of the rear triangle tubes 4 can be fitted to receive a standard bike tire. In some embodiments, a 27.5 inch bike tire can be adapted to be received by the rear triangle. The rear triangle tubes 4 can terminate in an adjustable dropout 50 for receiving a bike tire. Any sized bike tire could be used in various embodiments. The bike tire can be a road tire, a mountain tire, or a snow tire, for example.
In some embodiments, a frame mounted electric assist motor can be accommodated at the bottom bracket area. This would be located at the end of the seat tube 52 where it meets with the bottom tube 56 and both lower armatures of the lower rear triangle 4.
In some embodiments, the seat tubing 52 can be the industrial standard for the seat tubing to allow for seats to be inserted into the seat tube 52. A seat pin can be used, which can be based on industrial standards which can allow quick adjustments of the seat height and angle of the seat to the frame.
The material for the bike frame or any component of the bike can be metal, by way of example, aluminum, titanium, steel, alloys thereof or combinations thereof, or a composite material. Materials for some components, for example the kingpin, the diamond plate and the triangle plate, can be chosen based on the likelihood of damage caused by oxidation. For example, components that are likely to be scratched and exposed to elements can be made from materials such as stainless steel to provide added resistance to oxidation. Additionally, coatings can be added to the components to resist oxidation. Other components that are less likely to be exposed to oxidation can be made of materials that are susceptible to oxidation because the likelihood of such an exposure is low. For example, the shock cleats or a-arm cleat can be made from a plain steel instead of a stainless steel. Some components can be made of aluminum parts, for example suspension components. However, one skilled in the art would understand that the suspension parts can be made from other materials without deviating from the invention. One skilled in the art would also understand that the method used to attach the parts to each other will depend upon the material being used. For example, an epoxy or glue can be used to join composite materials or metal and composite materials, where a weld, solder, or braze can be used to join metal materials. Mechanical attachments can also be used, for example with bolts, etc. As an added measure of strength between the top tube 1 and bottom tube 2, an angle tube 5 can be interconnected (in some embodiments, it is welded) to the top tube 1 and the bottom tube 2. The angle between the angle support tube 5 and the bottom tube 2 can be between about 50° and about 130°. In one embodiment, there are at least two angled support tubes 5 on each side of the bike. In another embodiment, there is only one angled support tube 5 on each side of the bike. In some embodiments, no angled support tube 5 can be used.
As the vehicle is moved into a turned position, the center of wheel positions 8 and 10 are represented as dashed centerlines 11 and 12 and are perpendicular to dashed lines 13 and 14, which intersect at the center point 16. Once the dashed lines 13 and 14 intersect at center point 16, the wheels/tires will lean in the direction of a caster angle provided in the slant of the kingpin 34 (illustrated in
In some embodiments, the top tube 1 can have a thicker sidewall than the bottom tube 2 because the top tube 1 must be capable of resisting bending forces from shock 26, as these forces are transferred to the top tube 1. The cleats 23 are interconnected or welded directly to the bottom of the top tube 1. The cleats 23 are also centered between the bolted a-arm connections 18.
The shock cleats 23, which can be water jet cut, are interconnected or welded to the underside of the top frame tube 1, centrally located (within about plus or minus 5% from the center point) relative to the upper a-arm 24. The bottom shock connection is centrally located (within about plus or minus 5% from the center point) relative to the center bottom of a-arm 25 and is fastened with, by way of example, a bolt and lock nut. During rotational movement, the shock 26 moves with the lower a-arm 25 to dampen vibrational forces, hence providing a more comfortable and controlled ride for the operator.
The multidirectional super-swivel ball joints 22, are bolted to the top and bottom of the kingpin 27. The super-swivel ball joints 22 allow the wheel/tire to turn in the fore and aft direction, which allow turning from right to left.
Turning the handle bars mounted at the steering tube 3 (illustrated in
The shock 26 is mounted to lower a-arm 25, with the connector 35. In one embodiment, the camber 36 offset is provided by between about 0.75 inches and about 1.5 inches. In a preferred embodiment, the camber 36 offset is provided by about a one-inch offset. The camber 36 is dictated by both the movement of the swivel joint 22 and the a-arms 25, 24 during vehicle travel over uneven surfaces and throughout the duration of a turn.
The caster offset 34 is between about 0.75 inches and about 1.5 inches, in one embodiments. In a preferred embodiment, the caster offset 34 is about 1 inch.
In
The frame as described herein is illustrated in several pieces. However, the frame could be made of a single piece without deviating from the invention. Furthermore, in some embodiments, it is advantageous for the frame to be made of multiple pieces, so that the bike can be disassembled or be made collapsible allowing for ease of storage of the bike and further allowing the bike to become compact when not in use.
Ranges have been discussed and used within the forgoing description. One skilled in the art would understand that any sub-range within the stated range would be suitable, as would any number within the broad range, without deviating from the invention.
Accordingly, the present invention has been described with some degree of particularity directed to the exemplary embodiments of the present invention. It should be appreciated though that modifications or changes may be made to the exemplary embodiments of the present invention without departing from the inventive concepts contained herein.
The foregoing description of the present invention has been presented for purposes of illustration and description. Furthermore, the description is not intended to limit the invention to the form disclosed herein. Consequently, variations and modifications commensurate with the above teachings, and the skill or knowledge of the relevant art, are within the scope of the present invention. The embodiment described hereinabove is further intended to explain the best mode known for practicing the invention and to enable others skilled in the art to utilize the invention in such, or other, embodiments and with various modifications required by the particular applications or uses of the present invention. It is intended that the appended claims be construed to include alternative embodiments to the extent permitted by the prior art.
This application claims priority and benefit under 35 U.S.C. § 119(e) to U.S. Provisional Patent Application Ser. No. 62/448,837, filed on Jan. 20, 2017, which is incorporated herein in its entirety by reference. This application is related to the Taiwanese Patent Application No. 107102134, which is incorporated by reference in its entirety.
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/US18/14403 | 1/19/2018 | WO | 00 |
| Number | Date | Country | |
|---|---|---|---|
| 62448837 | Jan 2017 | US |
