Composite Wheel Assembly With Segmented Aero Disc Structure
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Solution Overview
Problem
The production of high-performance wheels for electric vehicles is hindered by the need for lightweight, aerodynamic designs that are costly and complex to manufacture, particularly with carbon fiber reinforced plastic (CFRP) materials, which are expensive and challenging to develop and maintain.
Innovation Solution
The solution involves dividing the 3D spoke structure or heavy monolithic disc into multiple non-planar components, allowing for automated manufacturing and the use of hybrid materials like CFRP and metal, with specific joining and manufacturing processes to create a load-bearing, aerodynamic, and aesthetically pleasing wheel design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If conventional monolithic spoke layout or aero wheel design is used, then aerodynamic performance is improved, but wheel weight increases significantly
Solution Approach 1:
The wheel is divided into multiple separate non-planar components including a rim, a hub, and multiple disc members arranged in a multi-layer configuration. This segmentation allows each component to be optimized independently for both aerodynamic performance and weight reduction, eliminating the need for heavy monolithic structures while maintaining the closed disc design for low drag resistance.
2Weight of moving object
If carbon fiber reinforced plastic (CFRP) wheels are used to compensate for weight, then wheel weight is reduced, but manufacturing cost and complexity increase
Solution Approach 1:
By segmenting the wheel into separate components, the manufacturing process becomes more manageable and less complex. Each disc member and component can be manufactured using standard techniques, and assembled together, avoiding the need for complex monolithic CFRP成型 processes while achieving weight reduction through material selection.
Solution Approach 2:
The invention utilizes composite materials including CFRP, glass fiber reinforced plastic (GFRP), and metal combinations in different wheel components. This allows optimization of each component's material properties for its specific function while maintaining overall weight reduction goals, and enables the use of hybrid manufacturing approaches that balance performance with manufacturing feasibility.
3Object-affected harmful factors
If closed wheel disc design is used for aerodynamics, then air drag is reduced, but structural integrity and manufacturing ease deteriorate
Solution Approach 1:
The closed disc design is achieved through multiple separate disc members arranged in layers rather than a single monolithic structure. This segmentation maintains the aerodynamic benefits of a closed disc while allowing each individual disc member to be manufactured more easily using standard techniques, and enables assembly of the complete wheel structure.
Solution Approach 2:
The invention transitions from a traditional planar wheel structure to a multi-layer three-dimensional configuration with disc members stacked and offset from each other. This dimensional change allows the closed disc design to be achieved while distributing structural requirements across multiple layers, improving both aerodynamics and manufacturability.
Data Source
AI summary
Methods for fabricating composite wheel assemblies are described, as well as the composite wheel assemblies being fabricated. The composite wheel assemblies may include multiple formed components that are joined together at one or multiple locations within the wheel assemblies, or may be fabricated as a castable wheel. The composite wheel assemblies may be fabricated from reinforced plastic and/or a metal.