Composite Vehicle Rim Assembly With NCF Subpreform Cavities
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Solution Overview
Problem
Existing vehicle rims made of fiber composite materials are complex, costly to produce, and lack the necessary robustness to withstand high loads, thermal stresses, and centripetal forces while being lightweight and rigid.
Innovation Solution
A vehicle rim design utilizing three subpreforms made of non-crimp fabric (NCF) with carbon, glass, or aramid fibers, where the second subpreform is inserted into connecting cavities formed by the first and third subpreforms, fixed with a binder, and infiltrated with resin, allowing for a continuous or discontinuous production process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional woven fabrics or non-crimp fabrics are used to produce fiber composite rim bodies, then the rim body can be manufactured, but the production process becomes complex and cost-intensive while the rim body lacks sufficient robustness against high loads and thermal stresses
Solution Approach 1:
The rim body is divided into multiple subpreforms (first, second, and third subpreforms) that can be manufactured separately and then assembled. This segmentation allows each subpreform to be optimized for specific structural requirements while simplifying the overall production process and enabling parallel manufacturing of multiple components.
Solution Approach 2:
The invention uses fiber composite materials consisting of reinforcement fibers (carbon, glass, or aramid) embedded in a resin matrix. The specific arrangement of subpreforms with connecting cavities creates a composite structure that enhances robustness against high loads and thermal stresses while maintaining manufacturing efficiency.
2Weight of moving object
If the rim body is made lightweight using fiber composite materials, then weight is reduced, but the structural rigidity and load-bearing capacity may be compromised
Solution Approach 1:
Different regions of the rim body are constructed with different subpreform configurations to provide locally optimized properties. The connecting cavities in the subpreforms create specific structural zones that enhance load-bearing capacity where needed while maintaining overall lightweight construction. The second subpreform positioned between the first and third subpreforms provides localized reinforcement.
Solution Approach 2:
The fiber composite material system with resin infiltration provides an optimal strength-to-weight ratio. The combination of high-strength reinforcement fibers (particularly carbon fibers) with the resin matrix creates a lightweight yet rigid structure capable of withstanding high loads and centripetal forces.
3Productivity
If three subpreforms are used with connecting cavities to enable parallel work steps and continuous production, then production time is reduced and manufacturing efficiency is improved, but the device complexity increases
Solution Approach 1:
The rim body is segmented into three subpreforms that can be manufactured independently and assembled through connecting cavities. This segmentation enables parallel production of multiple subpreforms, significantly reducing overall production time and enabling both continuous and discontinuous manufacturing processes.
Solution Approach 2:
The second subpreform is positioned between the first and third subpreforms and engages into connecting cavities formed by these subpreforms. This nested arrangement creates an integrated structure while allowing each subpreform to be produced separately, balancing structural complexity with manufacturing efficiency.
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 design results in a lightweight, rigid, and high-stress-bearing vehicle rim with improved durability and reduced production time, enabling efficient and cost-effective manufacturing.
Implementation Method 1
fixed thereat, for instance by means of the activation of a (preferably thermal) binder
Implementation Method 2
When all three subpreforms are penetrated by the same resin or resin mixture, a coherent, rigid but also particularly lightweight component is facilitated
Data Source
AI summary
The invention refers to a vehicle rim (1) with a rim body (2) made of fiber composite material, comprising a first subpreform (3) at a first axial end and a third subpreform (5) at the opposite second axial end, wherein a second subpreform (4) is arranged between the first subpreform (3) and the third subpreform (5), wherein the second subpreform (3) engages into a front connecting cavity (6) formed by the first subpreform (3) as well as also into a rear connecting cavity (7) being formed by the third subpreform (5). The invention also refers to a method for the production of a vehicle rim (1) with a rim body (2) made of fiber composite material, wherein an NCF material (19) comprising carbon fibers, glass fibers and/or aramid fibers is created respectively for the formation of a first subpreform (3) for a first axial end of the rim body (2) and of a third subpreform (5) for the opposite axial end of the rim body (2) with a connecting cavity (6, 7), respectively, wherein a second subpreform (4) made of a same or a similar NCF material (19) is inserted into the connecting cavity (6 and/or 7) and is fixed thereat.