Composite Wheel Rim with Encapsulated Attachment Inserts

Solution Overview

Problem

Existing composite wheel assemblies lack a robust and secure method for attaching and detaching wheel centers, limiting user customization and durability.

Innovation Solution

A composite wheel assembly with a radially inner and outer surface featuring attachment inserts between the layers, allowing for secure fastening of a wheel center using fasteners, and a method for manufacturing this assembly using a mold with a drop well region to retain the inserts between material layers.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If traditional materials (steel or aluminum) are used for wheel construction, then strength or weight is improved, but the ability to selectively change wheel center appearance is limited

Engineering Contradiction:

Improveability to change wheel center appearanceVSAvoidwheel strength

Core Design Contradiction:

Adaptability or versatilityVSStrength

Solution Approach 1:

The wheel assembly is divided into separate components: a composite wheel rim and a removable wheel center. This segmentation allows the wheel center to be changed independently while maintaining the structural integrity of the composite rim, thereby achieving both adaptability in appearance and strength in construction.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Attachment inserts are pre-integrated into the composite wheel rim during manufacturing. These pre-positioned inserts provide ready-made attachment points that enable easy installation and removal of different wheel centers, facilitating selective appearance changes without compromising the strength of the composite structure.

Inventive Principle:

Principle #10Preliminary action

2Adaptability or versatility

If composite materials are used for wheel construction, then weight is reduced and corrosion resistance is improved, but the ability to securely attach removable wheel centers is limited

Engineering Contradiction:

Improveremovable wheel center attachment capabilityVSAvoidattachment security

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

Attachment inserts are pre-integrated into the composite wheel rim during manufacturing. These pre-positioned inserts provide ready-made attachment points that enable easy installation and removal of different wheel centers, facilitating selective appearance changes without compromising the strength of the composite structure.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

Attachment inserts serve as intermediary components between the composite wheel rim and the wheel center. These inserts provide threaded or otherwise secure attachment mechanisms that bridge the gap between the composite material and the metal wheel center, ensuring reliable attachment while maintaining the lightweight composite structure.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Adaptability or versatility

If attachment inserts are integrated into composite wheel rim, then removable wheel center attachment is enabled, but manufacturing complexity increases

Engineering Contradiction:

Improvewheel center removabilityVSAvoidwheel rim manufacturing complexity

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

Attachment inserts are pre-integrated into the composite wheel rim during manufacturing. These pre-positioned inserts provide ready-made attachment points that enable easy installation and removal of different wheel centers, facilitating selective appearance changes without compromising the strength of the composite structure.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The manufacturing process merges the integration of attachment inserts with the composite wheel rim formation. By combining these operations into a single manufacturing step using a specialized mold, the process avoids separate attachment operations that would increase complexity, thereby enabling removable wheel centers while maintaining manufacturing efficiency.

Inventive Principle:

Principle #5Merging (Combining)

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

Enables secure and removable attachment of wheel centers, enhancing customization options and durability while maintaining a lightweight and corrosion-resistant composite structure.

Implementation Method 1

curing the first and second layers of material to form a wheel rim

Methodology Applied

Scientific EffectCuring: Photopolymerisation

Data Source

PatentUS11370246B2Composite wheel assembly and method of manufacturing

Publication Date: 2022.06.28 LACKS ENTERPRISES INC

AI summary

A composite wheel assembly and method of fabricating the same is provided. The wheel assembly includes a composite wheel rim, a wheel center, and a plurality of attachment fasteners for attaching the wheel center to the wheel rim. The wheel rim includes a plurality of attachment inserts that are configured to selectively engage with respective attachment fasteners. Each attachment insert is encapsulated by a plurality of composite layers of the wheel rim or is otherwise secured to the wheel rim. The attachment inserts extend from and/or are positioned within a drop well region of the wheel rim. The method of fabricating the wheel assembly includes forming first and second preforms and positioning the same onto a mold assembly. The method further includes positioning the attachment inserts between the first and second preforms such that the attachment inserts are secured therebetween.