Variable-Thickness Carbon Fiber Rim Ply Structure for Lightweight Strength
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Solution Overview
Problem
Current technologies lack a systematic structural design method for split carbon fiber composite rim structures, leading to inefficiencies in manufacturing and performance.
Innovation Solution
A variable thickness rim structure made of carbon fiber composite is designed using a three-sectional and symmetrically-stacked ply structure, with radially outer, axially outboard, and axially inboard ply blocks of varying thickness and angle, optimized for weight reduction, fatigue resistance, and impact resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If integrated wheel structures are used with carbon fiber composites, then strength and stiffness are improved, but manufacturing complexity and production cost increase
Solution Approach 1:
The wheel structure is divided into separate components: a hub and a rim, allowing independent manufacturing and assembly. The rim is further segmented into multiple ply blocks that can be manufactured separately and stacked to form the complete rim structure. This segmentation reduces manufacturing complexity while maintaining structural integrity and strength.
Solution Approach 2:
The patent utilizes carbon fiber composite materials with optimized ply arrangements to achieve high strength-to-weight ratio. The composite structure is designed with specific fiber orientations and stacking sequences to maximize mechanical properties while enabling simpler manufacturing processes compared to monolithic integrated wheels.
2Ease of manufacture
If uniform thickness is used for the rim structure, then manufacturing is simplified, but weight and strength performance deteriorate
Solution Approach 1:
The rim structure employs variable thickness design where different regions have different thicknesses optimized for their specific functional requirements. High-stress areas have increased thickness for strength, while low-stress areas have reduced thickness for weight savings. This local quality variation achieves optimal weight-strength balance while maintaining manufacturability through modular ply block construction.
3Weight of moving object
If variable thickness design is adopted for the rim, then weight is reduced and strength is optimized, but manufacturing complexity increases
Solution Approach 1:
The variable thickness rim is constructed from multiple discrete ply blocks that are stacked together. Each ply block can be manufactured with controlled thickness variations, and the stacking sequence is optimized to achieve the desired variable thickness profile. This segmentation approach manages structural complexity by breaking down the complex variable thickness geometry into manageable, repeatable units.
Solution Approach 2:
The patent utilizes the stacking dimension to achieve variable thickness in the radial direction. By varying the number of plies in different axial positions and using different ply block configurations, the desired three-dimensional variable thickness geometry is achieved. This dimensional approach transforms a potentially complex monolithic structure into a manageable stacked assembly.
4Ease of repair
If split assembled wheel structures are used, then maintenance and repair become easier, but structural integrity and manufacturing precision requirements increase
Solution Approach 1:
The wheel is designed as an assembled structure with separable hub and rim components, allowing the rim to be removed and replaced independently if damaged. The rim itself is constructed from modular ply blocks that can be manufactured with standardized interfaces, facilitating precise assembly while enabling easy maintenance and repair of individual components without affecting the entire wheel structure.
Data Source
AI summary
A variable thickness rim structure made of carbon fiber composite includes an outer ply block, that is paved as an outer side of the rim structure; an upper ply block, that is paved as an upper part of an inner side of the rim structure; a lower ply block, that is paved as a lower part of the inner side of the rim structure; a filling ply block, that is paved among the outer ply block, the upper ply block, and the lower ply block, where a first end of the upper ply block and a first end of the lower ply block extend inwards to form an annular connecting flange; a second end of the upper ply block extends upwards and a second end of the lower ply block extends downwards to form a rim ring together with the outer ply block.