Die-Cast Aluminum Wheel Rim With Thin Spokes and Low Drag

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Solution Overview

Problem

Existing methods for producing automobile rims from aluminum or aluminum alloys are not cost-effective and efficient, particularly when aiming for filigree structures and low flow resistance, as they require separate production and assembly of rim bed, rim center, and hub, and often result in excessive material usage due to solid rim center designs.

Innovation Solution

A method involving die casting to produce a single-piece automobile rim with a low wall thickness in intermediate spoke regions and a ring extending from the outer flange, overlapping the rim center, which are formed continuously in a casting mold, allowing for interconnected spokes and reduced material usage, enhancing aerodynamic properties and production speed.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If separate production and assembly of rim bed, rim center, and hub are used, then manufacturing flexibility is improved, but production time and cost increase

Engineering Contradiction:

Improvemanufacturing flexibilityVSAvoidproduction time

Core Design Contradiction:

Ease of manufactureVSProductivity

Solution Approach 1:

The patent merges the rim bed, rim center, and hub into a single integrated component produced by die casting. This eliminates the need for separate production and assembly operations, directly resolving the contradiction by combining multiple manufacturing steps into one continuous process, thereby reducing production time while maintaining manufacturing flexibility through the versatility of die casting

Inventive Principle:

Principle #5Merging (Combining)

2Strength

If solid rim center design is used, then structural strength is improved, but material usage increases

Engineering Contradiction:

Improvestructural strengthVSAvoidmaterial usage

Core Design Contradiction:

StrengthVSLoss of substance

Solution Approach 1:

The patent segments the rim center into multiple thin-walled sections separated by webs, rather than using a solid design. This segmentation maintains structural strength through the distributed web structure while significantly reducing material usage, directly addressing the contradiction between strength and material efficiency

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent applies local quality by providing different wall thicknesses in different regions of the rim center - thinner walls where less strength is needed and thicker webs where structural support is required. This optimized distribution of material maintains overall strength while minimizing total material usage

Inventive Principle:

Principle #3Local quality

3Strength

If thick wall design is used, then structural integrity is improved, but aerodynamic properties worsen

Engineering Contradiction:

Improvestructural integrityVSAvoidflow resistance

Core Design Contradiction:

StrengthVSObject-generated harmful factors

Solution Approach 1:

The patent applies local quality by using thin walls in the intermediate spoke regions where aerodynamic flow is critical, while maintaining thicker webs at structural connection points. This localized differentiation resolves the contradiction by providing thick walls only where structurally necessary and thin walls where aerodynamic performance is prioritized

Inventive Principle:

Principle #3Local quality

4Ease of manufacture

If traditional casting methods are used, then production cost is reduced, but cycle time increases

Engineering Contradiction:

Improveproduction costVSAvoidcycle time

Core Design Contradiction:

Ease of manufactureVSLoss of time

Solution Approach 1:

The patent replaces traditional sand casting or permanent mold casting mechanisms with die casting technology. Die casting uses high-pressure injection to fill molds rapidly, dramatically reducing cycle time compared to traditional methods while maintaining cost-effectiveness through the efficiency and automation of the die casting process

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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

This method enables rapid, cost-effective production of automobile rims with excellent aerodynamic properties and high load capacity while maintaining a filigree structure, achieving faster cycle times and improved load distribution through the use of die casting and optimized spoke designs.

Implementation Method 1

the automobile rim is produced in one piece and continuously in a casting mold by die casting of a casting material

Methodology Applied

Scientific EffectDie casting:

Data Source

PatentUS12023957B2Method for producing a motor vehicle rim from aluminium or an aluminium alloy for a wheel of a motor vehicle, and corresponding motor vehicle rim

Publication Date: 2024.07.02 AUDI AG

AI summary

A method for producing an automobile rim made of aluminum or an aluminum alloy for a wheel of an automobile, the automobile rim having a rim bed bounded on opposite sides by an outer flange and an inner flange, a hub with a center recess and a bolt circle, as well as a rim center connecting the rim bed and the hub to one another, the rim center being designed with a plurality of spokes spaced apart in the circumferential direction with respect to the longitudinal center axis of the automobile rim. The automobile rim is produced in one piece and continuously in a casting mold by die casting of a casting material, wherein the automobile rim has, at least in some areas, a low wall thickness not exceeding 15 mm.