Composite Rim Fiber Strip Layout for Continuous Stress Transfer
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Solution Overview
Problem
Conventional carbon fiber rim manufacturing methods are labor-intensive, result in inconsistent fiber directions, discontinuous stress transmission, and large gaps leading to poor structural integrity and low yield.
Innovation Solution
A composite rim design featuring an annular body with spirally disposed composite fiber strips aligned with an imaginary annular line, enhancing structural strength and flatness through continuous fiber alignment and interlacing, with ends aligned to the line for improved stress distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If carbon fiber sheets are pasted manually on an annular core, then the manufacturing process can be performed, but it is time-consuming and labor-intensive
Solution Approach 1:
The invention segments the continuous fiber reinforcement into multiple separate fiber strips that are pre-cut to specific lengths. These strips are then arranged in a overlapping pattern along the circumferential direction of the rim, eliminating the need for manual sheet-by-sheet application while maintaining continuous fiber reinforcement benefits.
Solution Approach 2:
The fiber strips are pre-cut and pre-positioned in their final arrangement pattern before the molding process. The overlapping regions are pre-planned and pre-positioned, so that during molding, the resin naturally flows through the overlapping regions without requiring manual adjustment or alignment during the molding process itself.
2Stability of the object's composition
If carbon fiber sheets are overlapped to form continuous structure, then coverage is improved, but directions of carbon fibers become inconsistent and discontinuous
Solution Approach 1:
The invention applies different fiber orientations to different regions of the rim structure. The fiber strips are arranged to follow the stress distribution pattern, with fibers oriented circumferentially in the sidewall regions and radially in the rim flange regions. This local optimization ensures that fiber directions are consistent within each region and aligned with the primary stress directions.
Solution Approach 2:
The invention transitions from two-dimensional sheet overlay to a three-dimensional arranged structure using multiple narrow strips. By using multiple strips arranged in an overlapping pattern along the circumferential direction, the system achieves continuous fiber reinforcement in multiple dimensions while maintaining consistent fiber directions within each strip.
3Stability of the object's composition
If carbon fiber sheets are overlapped, then coverage is improved, but large and uneven gaps occur at overlaps
Solution Approach 1:
The invention divides the fiber reinforcement into multiple narrow strips instead of using wide sheets. This segmentation allows for better control of overlap regions, as the narrower strips can be more precisely positioned and overlapped with uniform spacing. The overlapping pattern of multiple narrow strips creates a more uniform distribution of fiber coverage without large gaps.
Solution Approach 2:
The fiber strips are pre-cut to precise lengths and pre-positioned in their final overlapping arrangement before molding. This preliminary positioning ensures that the overlaps are uniform and gap-free, as the strips are already in their final positions when the resin is applied and cured.
4Ease of operation
If manual pasting of carbon fiber sheets is performed, then flexibility in application is maintained, but structural strength and flatness of the rim are poor
Solution Approach 1:
The invention optimizes fiber orientation locally according to the stress distribution in different regions of the rim. The fiber strips are arranged to follow the principal stress directions, with circumferential orientation in the sidewalls and radial orientation in the flanges. This local optimization of fiber alignment significantly improves structural strength while maintaining manufacturing flexibility.
Solution Approach 2:
The invention uses a composite structure combining multiple fiber strips with resin matrix, where the fibers are arranged in specific patterns to optimize mechanical properties. The overlapping arrangement of fiber strips creates a interlocked composite structure that enhances both strength and flatness while maintaining ease of application.
Data Source
AI summary
A composite rim is provided, including: an annular body extending around a center, an imaginary annular line being defined on an outer surface of the annular body, the imaginary annular line extending around the center; and at least one composite fiber strip, spirally disposed around the imaginary annular line for at least 360 degrees and attached to the outer surface of the annular body, opposing ends of each of the at least one composite fiber strip in a longitudinal direction of the at least one composite fiber strip being aligned with the imaginary annular line.