Coreless Disc Wheel Structure With Internal Bracing
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Solution Overview
Problem
Existing methods for manufacturing disc wheels, such as those using carbon fiber composite materials over honeycomb cores or structural foam cores, face challenges in achieving adequate bonding and optimal aerodynamics due to limitations in resin flow and pressure tolerance, leading to suboptimal strength and aerodynamic performance.
Innovation Solution
The introduction of internal braces, such as molded-in carbon fiber ribs, provides radial and axial structural support to disc panels, allowing for the formation of a stiff and lightweight all-composite disc wheel without a structural core, enabling better aerodynamics and power transfer without spokes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If carbon fiber composite material is molded over a honeycomb core, then structural support is provided, but adequate bonding is difficult to achieve due to resin flow limitations
Solution Approach 1:
The patent removes the honeycomb core from the manufacturing process entirely, creating a coreless disc wheel. This eliminates the bonding problem between carbon fiber and honeycomb core while maintaining structural integrity through the internal brace design. The extraction of the problematic component (honeycomb core) resolves the contradiction between achieving adequate bonding and manufacturing ease.
Solution Approach 2:
The patent uses carbon fiber composite material with internal braces to create a coreless structure. The composite material forms both the disc panels and the internal braces, creating a unified structure that provides structural support without requiring a separate core material. This composite approach eliminates bonding issues while maintaining strength.
2Strength
If structural foam core is used in sandwich construction, then additional structural support is provided, but pressure tolerance is limited leading to low curing pressures
Solution Approach 1:
The patent extracts the structural foam core from the design, creating a coreless disc wheel. This eliminates the pressure tolerance limitation of foam cores while maintaining structural support through internal braces made of carbon fiber composite material. The removal of the foam core allows for higher curing pressures without damaging a core material.
Solution Approach 2:
The patent replaces the foam core with carbon fiber composite internal braces that are molded as part of the disc panels. These composite braces provide the necessary structural support without the pressure tolerance limitations of foam materials, enabling stronger wheel construction at higher pressures.
3Shape
If honeycomb core is used for structural support, then manufacturing aid is provided, but optimal aerodynamics cannot be achieved due to flat side limitations
Solution Approach 1:
The patent removes the honeycomb core that constrained the side panels to flat shapes. Without the core material occupying space between the panels, the side panels can be molded with complex curved aerodynamic profiles. The internal braces are integrated into the panel structure rather than being separate core components.
Solution Approach 2:
The patent uses carbon fiber composite material to create integrated internal braces that are molded as part of the disc panels themselves. This allows the side panels to achieve complex aerodynamic shapes without being constrained by a separate honeycomb core, while the composite material provides the necessary structural support for these complex geometries.
4Ease of manufacture
If pre-impregnated carbon fiber is used, then material preparation is simplified, but resin flow into core material is prevented
Solution Approach 1:
The patent removes the core material from the design, eliminating the need for resin to flow into a core. Pre-impregnated carbon fiber can be used without compromising bonding, as there is no core material to bond to. The internal braces are formed from the carbon fiber itself rather than requiring separate bonding to a core.
Data Source
AI summary
A bicycle disc wheel comprises a first disc panel and a second disc panel. The first disc panel has a first side outer surface and a first side inner surface and the second disc panel has a second side outer surface and a second side inner surface. The first side outer surface radially extends from a first disc panel outer perimeter to a center opening and the second side outer surface radially extends from a second disc panel outer perimeter to the center opening. The second side inner surface faces the first side inner surface. A brace is coupled to the first side inner surface and the second side inner surface that provide radial and axial structural support to the disc panels.