Hybrid Vehicle Wheel Interface for Contact Corrosion Prevention
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Solution Overview
Problem
Wheels made from multiple materials face issues with electrochemical compatibility leading to contact corrosion, which affects durability and mechanical strength, especially when combining carbon fiber reinforced plastics with metals like aluminum, resulting in undesirable staining and reduced mechanical durability.
Innovation Solution
A wheel design featuring a rim and wheel center made from different materials, with an intermediate layer preventing direct contact between the rim and wheel center, comprising a hollow spoke structure and a sealing area to distribute load and prevent corrosion, using materials like stainless steel, titanium, or aluminum for the intermediate layer and electrically insulating materials for enhanced durability and corrosion resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If a rim made from carbon fiber reinforced plastic is combined with a metal wheel center, then the wheel weight is reduced and mechanical strength is improved, but contact corrosion occurs between the different materials leading to reduced durability
Solution Approach 1:
An intermediate layer made of electrically insulating material is introduced between the carbon fiber reinforced plastic rim and the metal wheel center. This intermediate layer acts as a mediator that prevents direct electrochemical contact between the dissimilar materials, thereby eliminating contact corrosion while allowing the hybrid material combination to maintain its weight and strength advantages.
2Reliability
If an intermediate layer is introduced between the rim and wheel center to prevent corrosion, then durability is improved, but device complexity increases
Solution Approach 1:
The intermediate layer is implemented as a thin film or coating applied to either the rim or wheel center surface. This thin-film approach provides the necessary electrical insulation and corrosion protection while adding minimal structural complexity and maintaining the overall simplicity of the wheel assembly.
3Weight of moving object
If different materials are used for the rim and wheel center, then weight is reduced and performance is improved, but electrochemical incompatibility leads to contact corrosion and staining
Solution Approach 1:
The intermediate layer made of electrically insulating material serves as a protective barrier that prevents electrochemical reactions between the carbon fiber reinforced plastic rim and metal wheel center. This mediator eliminates the harmful electrochemical compatibility issues while preserving the benefits of using dissimilar lightweight materials.
Solution Approach 2:
The intermediate layer creates an electrically inert environment between the two dissimilar materials by blocking electron transfer. This inert barrier prevents the electrochemical reactions that would otherwise occur at the interface of electrically conductive carbon fiber and metal materials.
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
The solution significantly enhances the durability and performance of the wheel by preventing contact corrosion and ensuring even load distribution, thereby improving the mechanical competence and aesthetic appeal while maintaining a low weight.
Implementation Method 1
an intermediate layer (22) is arranged between the at least one first (12) and the at least one second contact area (13) preventing at least partially direct contact between the at least one first (12) and the at least one second contact area (13)
Data Source
Figure 1~5
Figure 6~8
Figure 9~12
AI summary
The invention is directed to a wheel (1) comprising a rim (2) and a wheel center (3) interconnected to the rim (2). The wheel center (3) comprises at least one spoke (4) extending from a wheel hub (14) to the rim (2) in a radial direction. The rim (2) comprises per the at least one spoke (4) a first contact area (12) and the at least one spoke (4) comprises at its outer end a second contact area (13) which in a mounted position is aligned to the first contact area (12). The at least one spoke (4) comprises at least one hollow space (15) extending in the radial direction of the spoke (4).