Modular Multi-Part Wheel With Axial Rim Joint for Intricate Centers
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Solution Overview
Problem
Existing two-part wheels face challenges in manufacturing intricate designs due to extreme angles at the transition from the center part to the rim, leading to difficulties in applying materials like carbon fiber, and are prone to common damage that increases repair costs.
Innovation Solution
A two-part wheel design where the interface portion between the curb-side and car-side rim parts extends parallel to the center axis, allowing easier manufacturing of intricate designs, improved joining strength, and reduced repair costs by making the curb-side part replaceable.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the interface portion extends orthogonal to the center axis (conventional design), then a large surface area is available for attaching the two rim parts, but the center part cannot be manufactured easily when having an intricate design and extreme angles
Solution Approach 1:
The interface portion is reoriented from an orthogonal extension to a parallel extension relative to the center axis. This dimensional reorientation changes the geometry of the interface from a radial configuration to an axial configuration, eliminating extreme angles at the transition zones and enabling easier manufacturing of intricate center parts while maintaining sufficient bonding surface area.
2Strength
If the interface portion extends orthogonal to the center axis (conventional design), then the two rim parts can be attached with a large bonding surface, but the joining strength is reduced and handling robustness is compromised
Solution Approach 1:
By extending the interface portion parallel to the center axis rather than orthogonal to it, the design achieves superior joining strength. This axial alignment distributes mechanical loads more effectively across the interface, improving both handling robustness and manufacturing feasibility by eliminating extreme transition angles.
3Ease of repair
If the curb-side part comprises the entire wheel structure, then structural integrity is maintained, but repair costs increase when the most common wheel damage occurs
Solution Approach 1:
The wheel is divided into distinct modular components: a curb-side rim part and a car-side rim part with center part. This segmentation allows the curb-side portion, which is susceptible to common damage from curbs, to be replaced independently without replacing the entire wheel, thereby reducing repair costs while maintaining overall structural integrity through the robust interface portion design.
4Ease of manufacture
If extreme angles are present at the transition from center part to rim, then the wheel can accommodate intricate designs, but applying fiber sheets such as carbon fiber becomes difficult
Solution Approach 1:
The interface portion extension direction is changed from orthogonal to parallel with the center axis. This dimensional change eliminates extreme transition angles, creating smoother surfaces that are much more amenable to the application of fiber sheets and composite materials, while still allowing for intricate center part designs through the modified geometry.
Data Source
AI summary
A multi-part wheel 10 includes a curb-side rim part 11 and a car-side rim part 12, wherein the curb-side rim part 11 includes an outer rim-base portion 14, and the car-side rim part 12 includes an inner rim-base portion 14 and a center part 4.