Carbon Fiber Wheel Segmentation for Automated Resin Injection
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The production of carbon fiber composite wheels for motor vehicles is hindered by high costs due to reliance on handcraft methods, resulting in inconsistent mechanical performance and dimensional parameters, and high labor specialization.
Innovation Solution
A method involving dividing the wheel into small portions, mating them within a mold, injecting a resin at high pressure and temperature, and maintaining conditions for cross-linking to create a uniform resin matrix, minimizing specialized labor and ensuring consistent mechanical properties and dimensions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If handcraft methods are used to manufacture carbon fiber composite wheels, then high mechanical performance and low weight are achieved, but production costs increase and manufacturing consistency deteriorates
Solution Approach 1:
The wheel is divided into multiple portions (spokes and rim sections) that can be separately manufactured using automated processes, then assembled together. This segmentation allows industrialized production of individual components while maintaining the overall structural integrity and mechanical performance of the complete wheel assembly.
Solution Approach 2:
The patent utilizes carbon fiber composite materials combined with resin matrices to achieve high strength-to-weight ratio. The composite structure allows for optimized mechanical properties while enabling automated manufacturing processes, resolving the contradiction between high performance and ease of manufacture.
2Strength
If handcraft methods are used to manufacture carbon fiber composite wheels, then high mechanical performance is achieved, but manufacturing precision and dimensional consistency deteriorate
Solution Approach 1:
By dividing the wheel into standardized portions manufactured through automated processes, each component can be produced with consistent dimensional tolerances. The modular approach ensures repeatability and precision across production batches while maintaining structural performance.
Solution Approach 2:
The patent employs controlled parameters during the resin injection and curing processes (temperature, pressure, time) to ensure consistent material properties and dimensional accuracy. These controlled parameters enable industrialized production with high manufacturing precision.
3Strength
If handcraft methods are used to manufacture carbon fiber composite wheels, then high mechanical performance is achieved, but productivity decreases
Solution Approach 1:
The wheel design is segmented into multiple portions that can be manufactured simultaneously or in parallel using automated processes. This modular approach significantly increases production rate compared to handcraft methods, as multiple components can be produced concurrently and then rapidly assembled.
Solution Approach 2:
The patent replaces manual handcraft operations with automated resin injection molding and curing systems. This substitution of mechanical systems enables high-speed automated manufacturing while maintaining the structural integrity and mechanical performance of carbon fiber composite wheels.
4Strength
If handcraft methods are used to manufacture carbon fiber composite wheels, then high mechanical performance is achieved, but labor specialization requirements increase
Solution Approach 1:
The patent replaces skilled manual labor with automated resin injection molding machines and curing ovens. These automated systems perform the complex tasks of resin impregnation, void removal, and controlled curing, eliminating the need for highly specialized handcraft workers while maintaining product quality.
Solution Approach 2:
The automated manufacturing system performs self-service functions including automated resin injection, pressure control, temperature management, and curing monitoring. This self-service capability reduces dependency on specialized human operators and enables consistent high-quality production with less skilled labor.
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 approach enables the mass production of carbon fiber wheels with high mechanical performance, rigidity, and modest weight, reducing production costs while maintaining consistency, thus overcoming the limitations of handcraft methods.
Implementation Method 1
injecting into the mold a resin in the liquid state, said resin being injected at high pressure and high temperature for its diffusion in all the portions and through all the interface surfaces between them
Implementation Method 2
maintaining the pressure and temperature of the mold within predefined ranges for a time interval that is required for the at least partial cross-linking of the resin
Data Source
AI summary
A method for providing motor vehicle wheels made of composite material based on carbon fiber includes the steps of dividing each wheel into a plurality of portions having small dimensions; providing a a first portion with the terminal edges designed to mate with corresponding edges of a respective second portion; mating the portions, arranging them subsequently within a respective mold whose shape and dimensions are conjugate with respect to those of the wheel to be manufactured; and bringing the mold and its contents to a predefined temperature. The method further includes injecting into the mold a resin in the liquid state, the resin being injected at high pressure and high temperature, forming the matrix of the composite that constitutes the wheel; maintaining the pressure and temperature of the mold within predefined ranges for a time interval that is required for the at least partial cross-linking of the resin; and extracting the wheel from the mold.