Composite Rim Spiral Winding for Structural Strength

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Solution Overview

Problem

Conventional methods for manufacturing carbon fiber rims are labor-intensive, result in inconsistent fiber direction, poor structural integrity, and low yield due to manual application and overlapping of carbon fiber sheets.

Innovation Solution

A composite rim design featuring an annular body with composite fiber strips spirally disposed around an imaginary annular line for at least 360 degrees, providing excellent structural strength and flatness.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If manual pasting of carbon fiber sheets is used, then labor intensity is high and time-consuming, but the process can be easily implemented

Engineering Contradiction:

Improvemanufacturing efficiencyVSAvoidprocess complexity

Core Design Contradiction:

ProductivityVSEase of manufacture

Solution Approach 1:

The carbon fiber reinforcement is segmented into continuous strips that are pre-impregnated with resin. These strips are then automatically wound onto the rim blank in a continuous manner, eliminating the need for manual sheet-by-sheet application. This segmentation enables automated processing while maintaining manufacturing simplicity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The carbon fiber strips are pre-impregnated with resin before being applied to the rim blank. This preliminary action ensures proper resin distribution and eliminates the need for manual resin application during the winding process, thereby improving manufacturing efficiency without increasing process complexity.

Inventive Principle:

Principle #10Preliminary action

2Manufacturing precision

If carbon fiber sheets are overlapped manually, then fiber direction becomes inconsistent, but the manufacturing process remains simple

Engineering Contradiction:

Improvefiber direction consistencyVSAvoidstructural integrity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The carbon fiber strips are wound in a spiral pattern around the annular rim blank, creating a curved continuous path. This spiral winding ensures consistent fiber direction along the rim circumference while maintaining structural integrity through continuous stress distribution. The curved winding path eliminates directional inconsistencies associated with manual sheet overlapping.

Inventive Principle:

Principle #14Spheroidality (Curvature)

Solution Approach 2:

The carbon fiber strips are applied in a continuous spiral winding process rather than discrete overlapping sheets. This continuity ensures consistent fiber orientation and eliminates gaps or misalignments between sheets, thereby improving manufacturing precision and structural integrity simultaneously.

Inventive Principle:

Principle #20Continuity of useful action

3Manufacturing precision

If multiple carbon fiber sheets are layered manually, then labor intensity increases, but coverage can be improved

Engineering Contradiction:

Improvefiber coverage uniformityVSAvoidmanufacturing time

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

Instead of applying carbon fiber in discrete two-dimensional sheets that require manual layering, the invention uses continuous three-dimensional spiral winding. This dimensional change allows the fiber to cover the entire rim surface uniformly in a single continuous operation, improving coverage uniformity while reducing manufacturing time.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Solution Approach 2:

The spiral winding process applies carbon fiber continuously across the entire rim surface in one operation, eliminating the need for multiple discrete layering steps. This continuous application ensures uniform coverage while significantly reducing manufacturing time compared to manual sheet layering.

Inventive Principle:

Principle #20Continuity of useful action

4Reliability

If carbon fiber sheets with overlaps are used, then gaps and bubbles form, but the process is easier to implement

Engineering Contradiction:

Improvestructural strengthVSAvoidprocess simplicity

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The spiral winding follows a continuous curved path around the rim blank, eliminating sharp overlaps and gaps that occur with flat sheet application. This curved continuous path ensures complete coverage without voids, improving structural strength while maintaining process simplicity through automated winding.

Inventive Principle:

Principle #14Spheroidality (Curvature)

Solution Approach 2:

The continuous spiral winding process eliminates discrete overlaps between sheets, creating a seamless fiber layout. This continuity prevents gap formation and bubble entrapment that occur during manual sheet overlapping, thereby improving structural strength without complicating the manufacturing process.

Inventive Principle:

Principle #20Continuity of useful action

Data Source

PatentEP4406754B1Composite rim

Publication Date: 2025.05.21 MARSHAL INDUSTRIAL CORP

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AI summary

A composite rim (1) is provided, including: an annular body (10) extending around a center (C), an imaginary annular line (R) being defined on an outer surface of the annular body (10), the imaginary annular line (R) extending around the center (C); and at least one composite fiber strip (20), spirally disposed around the imaginary annular line (R) for at least 360 degrees and attached to the outer surface of the annular body (10), opposing ends (21) of each of the at least one composite fiber strip (20) in a longitudinal direction of the at least one composite fiber strip (20) being aligned with the imaginary annular line (R).