Composite Wheel Attachment Insert for Stiff Clamping Without Delamination
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Solution Overview
Problem
Attaching composite structures, such as carbon fibre wheels, to vehicle wheel mounts is challenging due to the low strength perpendicular to the fibre direction, leading to potential damage from high clamping pressures and the need for special fastener combinations that may not be compatible with standard wheel stud lengths.
Innovation Solution
An attachment arrangement featuring a fastening body with an engagement portion and an attachment insert that includes a bearing body with a fastening aperture and an insert section, where the engagement surface is recessed to accommodate shorter elongate fasteners, providing indirect clamping force and maintaining standard wheel stud lengths.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If high clamping pressure is applied to achieve a stiff joint, then joint stiffness is improved, but composite material damage occurs at or adjacent to the attachment hole
Solution Approach 1:
The attachment insert acts as an intermediary component between the fastener and the composite wheel. It includes a bearing body with a fastening aperture and an insert section that extends into the attachment aperture, distributing clamping forces away from the attachment hole edges and preventing delamination while maintaining joint stiffness
Solution Approach 2:
The attachment system is divided into separate functional components: the fastening body (bolt or nut), the attachment insert (with bearing body and insert section), and the composite wheel. This segmentation allows the insert to specifically address the composite material constraints while the fastener provides the clamping force
2Area of stationary object
If conventional flat washers are used to distribute load, then load distribution area is increased, but uneven load distribution creates high compression zones close to the attachment hole edge
Solution Approach 1:
The attachment insert provides locally optimized load distribution through its bearing body geometry. The insert section extending into the attachment aperture creates a graduated stress distribution pattern that eliminates concentration zones at the attachment hole edge, unlike conventional flat washers
3Object-affected harmful factors
If special fastener combinations are used to avoid material damage, then composite material protection is improved, but compatibility with standard wheel stud lengths is lost
Solution Approach 1:
The attachment insert serves multiple functions: it protects the composite material from damage, distributes clamping forces evenly, and maintains compatibility with standard wheel stud lengths. The bearing body provides a clamping surface while the insert section extends into the attachment aperture to protect the composite, making the system universally applicable
Data Source
AI summary
An attachment arrangement for attaching a composite wheel to a wheel mount, including an attachment aperture that receives an elongate fastener element. A fastening body, including or fastened to the elongate fastener element, has an engagement portion and an attachment insert including a bearing body, a fastening aperture, and an insert section extending axially away from the bearing body and into the attachment aperture. An engagement surface, located at least in part between the bearing body and a distal end of the insert section, extends from an inner surface of the insert section and is configured complementary to and engages the fastening body engagement portion. The insert section distal end extends into the attachment aperture and is spaced from the wheel mount, or from or in an element in, on, integral with, or adjacent to the wheel mount, without directly engaging the wheel mount and/or element.