Composite Rim Braking Track Reinforced Prepreg
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Solution Overview
Problem
Conventional braking tracks on composite rims, particularly carbon fiber/epoxy composite rims, suffer from unrecoverable damage and safety concerns due to direct friction with rubber brake shoes, leading to fiber exposure, scratches, and inconsistent braking performance, which is exacerbated by sand and mud, and existing reinforcement methods fail to adequately address weight and durability issues.
Innovation Solution
A reinforced prepreg comprising a fiber fabric and a mixture of resin with needle-shaped crystals of microscale or nanoscale sizes is applied to the braking track, enhancing abradability and interfacial strength without increasing weight, using materials like LCP, carbon, glass, or basalt fibers with ZnO, ZnS, MgO, Al2O3, SiC, or SiN crystals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a surface layer with increased thickness (0.1 mm to 0.3 mm) is formed on the braking track to improve wear resistance, then the protection against damage is enhanced, but the weight of the composite rim increases
Solution Approach 1:
The patent applies composite materials by combining fiber fabric (carbon fiber, glass fiber, or basalt fiber) with a resin matrix containing needle-shaped crystals (such as alumina, silica, or titania). This composite structure provides enhanced wear resistance and mechanical strength without requiring increased thickness, thus avoiding additional weight while improving the protective function of the braking track surface layer
Solution Approach 2:
The patent changes the physical and chemical parameters of the surface layer by incorporating needle-shaped crystals with specific size distributions (microscale and nanoscale) into the resin matrix. These parameter changes at the material level significantly improve wear resistance and interfacial strength, allowing the braking track to withstand friction and sand abrasion without increasing thickness or weight
2Reliability
If conventional fiber fabric prepreg is used to reinforce the braking track, then basic protection is provided, but the abradability is insufficient and damage occurs under sand and mud conditions
Solution Approach 1:
The patent creates a composite material system where needle-shaped crystals (alumina, silica, titania) are dispersed in the resin matrix alongside fiber fabric. This composite structure provides superior resistance to sand and mud abrasion compared to conventional fiber fabric alone, as the hard crystals protect the fibers from mechanical damage while maintaining flexibility and structural integrity
Solution Approach 2:
The patent applies local quality enhancement by concentrating needle-shaped crystals at the braking track surface where friction and sand contact occur. This localized reinforcement provides targeted protection against abradability without affecting the overall weight or structural properties of the composite rim, addressing the specific harmful factor of sand and mud damage
3Reliability
If the thickness of the surface layer is increased to defer damage generation, then damage prevention is improved, but the weight increases and damage prevention remains limited
Solution Approach 1:
The patent uses composite materials with needle-shaped crystals embedded in the resin matrix to achieve high damage resistance at reduced thickness. The crystals provide structural reinforcement and crack propagation resistance, allowing the surface layer to be thinner while maintaining or improving damage prevention capabilities, thus reducing weight without compromising reliability
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
The solution significantly improves wear resistance, with the reinforced prepreg demonstrating at least eight times higher abradability compared to conventional methods, maintaining structural integrity and braking performance even in wet mud conditions, and reducing the risk of fiber exposure and damage.
Implementation Method 1
The wear-resistant layer structure of the braking track... significantly improves wear resistance, with the reinforced prepreg demonstrating at least eight times higher abradability compared to conventional methods
Implementation Method 2
A reinforced prepreg comprising a fiber fabric and a mixture of resin with needle-shaped crystals... enhancing abradability and interfacial strength
Data Source
AI summary
A reinforced prepreg which is applied to a wear-resistant layer structure of a braking track is provided. The reinforced prepreg includes a fiber fabric and a mixture mixed with the fiber fabric. The mixture includes a resin and a plurality of needle-shaped crystals having microscale or nanoscale sizes mixed with the resin.