Segmented Wheel Hub With Enclosed Void And Overmolded Covering
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Solution Overview
Problem
Existing wheel designs lack multipart hubs that provide additional strength and stability, which is essential for heavier load applications and improved durability.
Innovation Solution
A wheel design featuring a main hub portion with an outer and inner portion separated by a sidewall, a ring portion that engages to create an enclosed void, and an exterior covering that surrounds the assembled hub, providing structural support and resilience similar to an air-filled tire.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a single-piece hub is used, then the manufacturing process is simple, but the structural strength and stability are insufficient for heavier load applications
Solution Approach 1:
The hub is divided into multiple segments (first hub segment, second hub segment, third hub segment) that are assembled together to form the complete hub. This segmentation allows each part to contribute to the overall structural strength while enabling modular manufacturing and assembly, resolving the contradiction between strength and manufacturing simplicity.
2Strength
If air-filled tires are used to provide resilience, then the wheel can handle heavier loads, but the complexity of the wheel structure increases
Solution Approach 1:
The patent replaces complex air-filled tire systems with a simpler molded resilient exterior covering that provides similar shock-absorbing functionality. This exterior covering is molded directly onto the hub segments, eliminating the need for separate air tire components while maintaining load capacity and resilience.
3Stability of the object's composition
If a multipart hub with enclosed void is created, then the structural integrity is improved, but the manufacturing process becomes more complex
Solution Approach 1:
The hub segments are pre-formed with engagement features (protrusions and recesses) that facilitate straightforward assembly. The enclosed void is created during the molding process of the exterior covering, which is applied after hub assembly. This preliminary preparation of components with built-in alignment features simplifies the overall manufacturing process despite the multipart construction.
4Reliability
If the exterior covering is molded over the assembled hub, then the components are securely bonded, but the manufacturing process requires precise timing and positioning
Solution Approach 1:
The hub segments are assembled with engagement features that ensure proper positioning before the exterior covering is molded. This preliminary assembly with built-in alignment mechanisms (protrusions fitting into recesses) ensures that when the exterior covering is molded over the assembled hub, the components are automatically positioned correctly, achieving reliable bonding without requiring complex positioning procedures during molding.
Data Source
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AI summary
A wheel (10) includes a main hub portion (20) having outer and inner portions, the inner portion being spaced from the outer portion by a main hub sidewall; a ring portion (30) configured to engage the main hub portion so as to enclose the outer portion and the inner portion and create an enclosed void; and an exterior covering (50) surrounding at least part of the main hub portion and the ring portion at the enclosed void. A method of forming a wheel includes forming a main hub portion having an outer portion and an inner portion; forming a ring portion configured to engage the main hub portion so as to enclose the outer portion and the inner portion and create an enclosed void; assembling the main hub portion and the ring portion into an assembled hub; and overmolding an exterior covering surrounding at least part of the main hub and ring portions.