Fiber-Reinforced Spoke Star Structure With Loop Load Transfer
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Solution Overview
Problem
Existing methods for producing spoked wheels with fiber composite materials require complex and expensive preformed mold elements, limiting production flexibility and fiber utilization efficiency.
Innovation Solution
A spoke star made of fiber-reinforced plastic with double spokes forming a closed ring, where the fibers run parallel from the hub-side inner circumference to the rim-side outer circumference, allowing for efficient load transfer and reduced weight through optimized fiber orientation and loop connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If preformed mold elements are used to shape the rim, then the rim can be given its desired shape, but the manufacturing complexity and cost increase significantly
Solution Approach 1:
The patent extracts the shaping function from complex preformed mold elements and transfers it to the fiber bundle arrangement itself. The fiber bundles are tensioned and routed between hub and rim to directly define the spoke star geometry, eliminating the need for separate shaping molds while maintaining precise rim shape control
Solution Approach 2:
The fiber bundles are pre-tensioned and pre-routed in the desired spoke star configuration before final rim formation. This preliminary positioning of fibers along the intended spoke paths allows the rim to take shape without requiring complex mold elements, as the fiber arrangement itself guides the structural formation
2Adaptability or versatility
If preformed mold elements are used, then a particular type of spoked wheel can be produced, but production flexibility and adaptability are reduced
Solution Approach 1:
The system transitions from static preformed molds to a dynamic fiber routing system where fiber bundles can be tensioned, routed, and arranged in different configurations. This allows the same manufacturing approach to produce various spoke star types and sizes by simply repositioning the fiber bundles rather than changing entire mold assemblies
Solution Approach 2:
The fiber bundle system serves multiple functions: it provides structural reinforcement, defines the spoke star geometry, and enables production flexibility. By using the same fiber-based mechanism for both structural and shaping purposes, the system can adapt to different wheel types without requiring specialized molds for each configuration
3Loss of substance
If conventional fiber mat methods are used, then the rim can be formed, but fiber utilization efficiency is suboptimal
Solution Approach 1:
Instead of using uniform fiber mats, the patent applies fiber bundles with specific orientations and tension levels at specific locations. The fiber bundles are routed to follow the exact stress paths in the spoke star, concentrating material where it is most needed for structural strength while minimizing waste in areas with lower stress requirements
Data Source
AI summary
A spoke star is made of a fiber-reinforced plastic and formed as a star-shaped closed ring, the spoke star having spokes between a hub-side inner circumference of the spoke star and a rim-side outer circumference of the spoke star, a single fiber bundle running repeatedly in the spoke star between the inner circumference and the outer circumference along spokes of the spoke star. The spokes may be formed as double spokes, the spokes having a loop at the rim-side outer circumference of the spoke star. The loops allow for a better load transfer to the spoke star.