Composite Wheel Spoke-to-Rim Connector for Load Transfer
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Solution Overview
Problem
Current composite wheels lack an effective means for load transfer between the rim portion and the back of the spokes, leading to high stress regions and suboptimal load distribution, particularly under certain loading conditions.
Innovation Solution
A spoke-to-rim reinforcing connector with a continuous fibre orientation that extends substantially perpendicular to the spoke axis, featuring a spoke saddle and rim tabs that wrap around the spoke and rim fibre layups, facilitating effective load transfer between the rim and face structures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If folding tabs are used to connect rim and spoke fibre layups, then the rim and face portions can be interconnected, but effective load transfer between the rim portion and the back of the spokes is not achieved
Solution Approach 1:
The connector extends in multiple dimensions with rim tabs extending into the rim fibre layup and a spoke saddle wrapping around the spoke, creating a three-dimensional load transfer path that addresses both connection strength and load transfer efficiency simultaneously
Solution Approach 2:
The connector is formed from continuous fibre composite material with fibres oriented substantially perpendicular to the spoke axis, matching the load paths and providing both strength and reliable load transfer through the composite structure
2Ease of manufacture
If fibre orientation is not aligned with load paths, then manufacturing is simpler, but high stress regions occur and load transfer is suboptimal
Solution Approach 1:
The fibre orientation is specifically configured in the connector to be substantially perpendicular to the spoke axis, creating local quality that matches the load transfer requirements at the spoke-to-rim connection while maintaining overall manufacturing feasibility
Solution Approach 2:
The fibre orientation parameter is changed from conventional alignments to be perpendicular to the spoke axis, optimizing the mechanical performance by aligning fibres with the actual load paths experienced during wheel operation
Data Source
AI summary
A spoke-to-rim reinforcing connector of a composite wheel. The composite wheel has a rim portion with a complementary rim fibre layup and a circumferential axis, and a face portion with a hub and spokes interconnecting the rim portion and the hub, each spoke having a complementary spoke fibre layup. The spoke-to-rim reinforcing connector comprises at least one spoke saddle and at least two rim tabs. The spoke saddle has a seat portion extending around an end portion, about the spoke axis, and over a face surface of the spoke fibre layup, and at least two spoke legs that extend over the sides of the spoke fibre layup. Each rim tab extends from a spoke leg perpendicularly to the spoke axis and is configured to be incorporated into the rim fibre layup. The connector has a continuous body having a fibre orientation extending perpendicular to the spoke axis.