Foam-Reinforced Composite Sidewalls for Lightweight Strength
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Solution Overview
Problem
Existing composite materials used in bicycle frames and rims face challenges in achieving a balance between being lightweight and maintaining high mechanical strength, as overly thin structures are prone to rupture under torque while overly thick structures are not lightweight enough.
Innovation Solution
The use of a composite material structure featuring reinforced fiber bodies with embedded foam components between rib portions in the sidewalls, which supports and reinforces the structure, providing both lightweight and high mechanical strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the walls of the finished structures are made thick, then the mechanical strength is improved, but the weight increases
Solution Approach 1:
The patent applies local quality by embedding foam components specifically in the sidewalls where structural support is needed, rather than uniformly thickening the entire structure. This localized reinforcement provides mechanical strength where required while maintaining lightweight characteristics in other areas.
Solution Approach 2:
The patent uses composite materials by combining reinforced fiber material with foam components to create a hybrid structure. The composite construction integrates the high strength-to-weight ratio of fibers with the lightweight cushioning properties of foam, achieving both strength and weight reduction goals.
2Weight of moving object
If the walls of the finished structures are made thin, then the weight is reduced, but the structure becomes prone to rupture under torque
Solution Approach 1:
The foam components are strategically positioned in the sidewalls to provide localized reinforcement against torque-induced stress. This allows the overall wall thickness to remain thin for weight reduction while specific areas gain enhanced rupture resistance through the embedded foam support.
Solution Approach 2:
The foam components are embedded during the manufacturing process before the structure is put into service. This preliminary integration ensures that the reinforcement is already in place to prevent rupture under future torque loads, rather than adding protective measures after the fact.
3Strength
If foam components are embedded in sidewalls, then mechanical strength is enhanced, but manufacturing complexity increases
Solution Approach 1:
The patent merges the foam component embedding process with the existing additive manufacturing process for creating reinforced fiber structures. By integrating both operations into a single manufacturing workflow, the patent enhances mechanical strength while minimizing the increase in manufacturing complexity that would result from separate processing steps.
Data Source
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AI summary
An article made by composite material includes a body made of reinforced fiber. The body has at least two opposing sidewalls. A foam component is embeddedly disposed in each sidewall. Owing to the two foam components, the article made by composite material is lightweight and has high mechanical strength.