Composite Vehicle Wheel Hub for Corrosion-Safe Load Transfer
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Solution Overview
Problem
Wheels made partially from fiber-reinforced plastic materials face challenges in corrosion prevention and stress concentration, particularly at material interfaces, which affect efficient load transfer from the vehicle hub to the wheel.
Innovation Solution
A wheel design featuring a metallic support cover with a three-dimensional shape, integrated into the hub, that includes bushings with frusto-conical surfaces to pre-tension fibers and improve stress distribution, combined with an additional intermediate layer for corrosion prevention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If a wheel is made partially from fiber-reinforced plastic material to minimize vehicle mass, then weight is reduced, but corrosion prevention and stress distribution at material interfaces become problematic
Solution Approach 1:
The patent employs a composite structure combining fiber-reinforced plastic material for the wheel rim and spokes with a metallic support cover at the hub. This composite material approach allows the wheel to maintain low weight while the metallic hub provides corrosion resistance and proper stress distribution characteristics, resolving the contradiction between weight reduction and reliability at material interfaces
Solution Approach 2:
The patent applies different material properties to different regions of the wheel: the fiber-reinforced plastic is used where weight reduction is critical (rim and spokes), while the metallic support cover is applied at the hub where structural integrity, corrosion resistance, and stress distribution are paramount. This local differentiation resolves the contradiction by optimizing each region for its specific functional requirements
2Reliability
If a metallic support cover is added to improve load transfer and stress distribution, then reliability is improved, but device complexity increases
Solution Approach 1:
The metallic support cover is designed to be integrally formed with the hub, merging the support function into the existing hub structure rather than adding a separate component. This integration improves load transfer efficiency while minimizing the increase in device complexity by combining multiple functions into a single unified structure
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
Enhances load transfer efficiency and stress/strain distribution while minimizing corrosion, maintaining a continuous wheel surface and avoiding peak loads.
Implementation Method 1
Each first outer surface (11) is configured to apply an expanding force on the corresponding first inner surface (12) of the fiber-reinforced plastic material of the hub when the first bushing (9) is inserted into the bushing-opening (10)
Implementation Method 2
The reinforcing fibers or fiber bundles (23) at least partially encircle the at least one first bushing (9)
Implementation Method 3
The reinforcing fibers at least partially encircle the at least one first bushing (9)
Data Source
Figure 1~2
Figure 3~5
Figure 6
AI summary
The present invention is directed to a wheel (1) for a vehicle comprising a rim (2) and a wheel center (3). The wheel center is comprising several spokes (4) extending from a hub (5), comprising a center opening (6), radially outwards to the rim (2). The hub (5) is made from a fiber-reinforced plastic material and is covered on the outboard side from a three-dimensionally shaped support cover (7) made from metallic material. The present invention is further directed to a method for manufactoring such a wheel.