Multi-Piece Extrusion Spokes for Wheel Strength
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Solution Overview
Problem
Conventional high-performance wheels face challenges in minimizing bending forces and optimizing load distribution, particularly during cornering and crash scenarios, due to their structural design which often requires assembly of multiple parts and may suffer from stress concentrations and fretting corrosion.
Innovation Solution
The wheel assembly features a multi-piece extrusion design with triangular prism-shaped spokes that are removably connected to a hub and rim, using a form-press-fit scheme, and can be fabricated from materials like aluminum or carbon fiber, with surface treatments to reduce stress concentrations and fretting, allowing for improved load distribution and crash resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional forgings or flow-forming are used for high-performance wheels, then structural strength is improved, but bending forces increase and weight to load ratio deteriorates
Solution Approach 1:
The wheel is divided into multiple separate extruded components (spokes, rim sections, hub elements) that are assembled together. Each component is optimized independently to carry specific loads primarily in tension and compression, minimizing bending forces while maintaining overall structural strength.
Solution Approach 2:
The patent transitions from traditional radial spoke arrangements to a triangular lattice structure that adds geometric dimensionality. This triangular configuration creates truss-like elements that efficiently distribute loads through tension and compression members, reducing bending moments compared to conventional solid wheel designs.
2Force
If multiple parts are assembled to create triangular structure, then bending forces are minimized, but device complexity increases
Solution Approach 1:
Multiple extruded components are designed with integrated connection features that allow them to be assembled into a unified triangular lattice structure. The components merge to form a cohesive wheel assembly that maintains structural integrity while minimizing bending forces through the triangular geometry.
3Ease of manufacture
If conventional wheel designs are used, then manufacturing is simpler, but stress concentrations and fretting corrosion occur
Solution Approach 1:
Each extruded component is designed with optimized local geometries that distribute stresses evenly throughout the structure. The triangular lattice configuration and carefully designed connection points eliminate stress concentrations by avoiding sharp corners and abrupt cross-section changes, while the extrusion process allows for smooth, continuous grain flow that enhances fatigue resistance.
4Weight of moving object
If extruded components are used for triangular structure, then weight to load ratio is optimized, but manufacturing precision requirements increase
Solution Approach 1:
The wheel is segmented into multiple extruded components that can be manufactured independently with standard extrusion tolerances. Each component's geometry is optimized for the extrusion process, allowing for efficient production while maintaining the lightweight triangular lattice structure. The modular nature of segmentation allows for easier quality control compared to a single complex extrusion.
Data Source
AI summary
A wheel assembly is provided that includes spokes having one or more triangular prisms positioned between inner and outer surfaces of the spokes that impart additional strength.