Composite Wheel Tread Design for Noise Reduction
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Solution Overview
Problem
Plastic wheels used in refuse carts and similar applications often produce noise and are prone to chipping, fracturing, and breakage, especially under heavier loads, due to their material properties and interaction with surfaces.
Innovation Solution
A wheel design featuring an inner plastic section and an outer rubber or rubber-like section mechanically coupled to the inner section, where the outer section covers the ground-facing surface and extends below the hub-facing surface, allowing for materials that do not chemically bond with each other, thereby reducing noise and protecting the inner section from damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If plastic wheels are used, then manufacturing cost is reduced and ease of manufacture is improved, but noise is increased and durability is worsened
Solution Approach 1:
The wheel combines plastic and rubber materials in a composite structure where the plastic inner section provides structural support and the rubber outer section provides noise reduction and durability. This composite approach allows each material to contribute its advantageous properties while mitigating their individual disadvantages.
Solution Approach 2:
The wheel is divided into two distinct segments: an inner plastic section and an outer rubber section. This segmentation allows each part to be optimized for its specific function - the plastic inner section for structural integrity and the rubber outer section for noise damping and surface protection.
2Ease of manufacture
If plastic wheels are used, then manufacturing cost is reduced, but durability is worsened due to chipping and fracturing
Solution Approach 1:
The composite structure combines the cost-effectiveness of plastic with the durability of rubber. The rubber outer section protects against chipping and fracturing while the plastic inner section maintains structural integrity, achieving both economic and reliability goals.
Solution Approach 2:
The rubber outer section acts as a protective cushion that absorbs impacts and stresses before they reach the plastic inner section, preventing chipping and fracturing before they can occur.
3Reliability
If rubber is chemically bonded to plastic, then durability is improved, but manufacturing complexity is increased
Solution Approach 1:
The molding process creates self-contained features within each section that enable mechanical interlocking. The inner plastic section has integrated features such as recesses, protrusions, or undercuts that automatically engage with corresponding features in the rubber outer section during molding, eliminating the need for separate bonding operations.
4Shape
If thick tread is used for aesthetic appeal, then appearance is improved, but material usage and cost are increased
Solution Approach 1:
The tread design extends in multiple dimensions - radially outward for thickness and aesthetically, but also wraps around to cover the hub-facing surface. This multi-dimensional coverage creates a thick-tread appearance from multiple angles while optimizing material distribution to reduce overall material usage.
Data Source
AI summary
Wheels and methods of making wheels are disclosed including an inner portion and a tread mechanically coupled to the inner portion. The tread may be mechanically coupled to the inner portion on an inside and an outside of the wheel. The inner portion may include a rim including a plurality of apertures. The inner portion may be high density polyethylene and the tread may be thermoplastic elastomer.