Composite Wheel Multi-Resin Layup for Seamless Reinforcement
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Solution Overview
Problem
Existing composite wheel manufacturing processes compromise on strength, temperature performance, and cost due to the use of a single resin or material matrix across the entire wheel, leading to undesirable overlaps or seams in reinforcement layers.
Innovation Solution
A composite wheel structure with a continuous fiber reinforcement layer and multiple resin chemistries at different axial sections, achieved by impregnating chopped fibers with different resins on carrier films or prepregs, allowing for tailored strength and temperature characteristics in specific zones.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the same resin or material matrix is used for the entire wheel construction, then the manufacturing process is simplified, but the wheel must compromise between strength, temperature performance, and cost
Solution Approach 1:
The patent applies local quality by using different resin chemistries in different axial zones of the wheel. The first axial section uses a first resin chemistry optimized for its specific requirements, while the second axial section uses a second resin chemistry with different properties. This allows each zone to have the optimal material properties for its function without compromising overall wheel performance or manufacturing feasibility.
2Strength
If different resins are used for different portions of the wheel, then strength and temperature performance at different locations is improved, but the wheel construction becomes more complex with multiple layers and overlaps
Solution Approach 1:
The patent merges multiple resin-impregnated fiber layers into a single integrated wheel structure. By using fiber reinforcement that continuously spans across the axial interface between different resin zones, the patent eliminates the need for separate overlapping layers. The resins are applied to different sections of the same continuous fiber structure, creating a unified wheel construction that avoids the complexity of multiple discrete layers while maintaining differentiated material properties.
3Strength
If different resins are used for different portions of the wheel, then tailored strength and temperature performance is achieved, but material costs increase
Solution Approach 1:
The patent applies local quality by using different resin chemistries in different axial zones of the wheel. The first axial section uses a first resin chemistry optimized for its specific requirements, while the second axial section uses a second resin chemistry with different properties. This allows each zone to have the optimal material properties for its function without compromising overall wheel performance or manufacturing feasibility.
4Strength
If reinforcement layers are overlapped to achieve different properties at different portions, then localized strength is improved, but bulky seams are created
Solution Approach 1:
The patent merges multiple resin-impregnated fiber layers into a single integrated wheel structure. By using fiber reinforcement that continuously spans across the axial interface between different resin zones, the patent eliminates the need for separate overlapping layers. The resins are applied to different sections of the same continuous fiber structure, creating a unified wheel construction that avoids the complexity of multiple discrete layers while maintaining differentiated material properties.
Data Source
AI summary
A composite wheel structure is made from a fiber-reinforced molding compound (FRMC) material having different resins at different axial sections of the wheel. The FRMC material can be provided as a roll of material, with different resin chemistries at different lateral sections, and applied to a wheel mold such that the different resin chemistries are provided at different axial sections. A single carrier film may have different resin chemistries at different sections, and chopped reinforcement fibers can be deposited across the width of the film. Multiple separate carrier films with different resin chemistries can be arranged side by side, and the chopped fibers added to the combined width. Reinforcing material can be provided in a prepreg and chopped and added to single carrier film at different width sections. The chopped fibers and different resins can be impregnated together to define the multi-resin FRMC material for use in the wheel layup.