Thermoplastic Vehicle Wheel Rib Network Design
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Solution Overview
Problem
Existing thermoplastic polymer wheels lack optimized geometry, leading to suboptimal performance under various external constraints such as static and dynamic forces, high temperatures, and chemical stresses, while also being heavy, which affects aerodynamics, fuel consumption, and overall vehicle performance.
Innovation Solution
A vehicle wheel design featuring a rim, hub, and disc with a network of ribs made from thermoplastic polymer, optimized for maximum section inertia to minimize stress, using a cylindrical hub with annular walls and ribs arranged tangentially to absorb forces and torques, and incorporating metal inserts for added strength and stability, with a manufacturing process involving welding injection or fusible core technology.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a thermoplastic polymer wheel is made with conventional geometry, then the manufacturing process is simplified, but the mechanical strength and stress resistance are insufficient
Solution Approach 1:
The wheel structure is segmented into multiple functional components: a rim, a hub, and a disc with a network of ribs. This segmentation allows each part to be optimized for its specific function while maintaining overall structural integrity and stress resistance.
Solution Approach 2:
The patent employs curved and optimized geometric forms in the wheel design, including the cylindrical hub and the arc-shaped ribs that connect tangentially. These curved geometries distribute stress more effectively compared to straight-line constructions, enhancing mechanical strength.
2Weight of moving object
If the wheel mass is reduced to improve aerodynamics and fuel consumption, then the aerodynamic performance improves, but the mechanical strength and stress resistance deteriorate
Solution Approach 1:
Different regions of the wheel are assigned different material properties and structural characteristics. The rim, hub, and disc areas have optimized local geometries and material distributions that provide maximum strength where needed while minimizing mass in less critical areas, achieving a high strength-to-weight ratio.
Solution Approach 2:
The wheel utilizes composite construction with the thermoplastic polymer matrix reinforced with strategic structural elements. The combination of the polymer material with the optimized rib network and hub structure creates a composite system that achieves high strength with reduced mass.
3Stress or pressure
If the wheel structure is optimized for maximum section inertia to minimize stress, then the stress levels decrease, but the manufacturing complexity increases
Solution Approach 1:
The patent transitions from traditional two-dimensional wheel designs to a three-dimensional optimized structure with vertically extending ribs and a cylindrical hub. This dimensional enhancement allows for maximum section inertia and stress distribution while maintaining manufacturability through advanced molding techniques.
4Temperature
If the wheel is designed with cooling features to manage high temperatures during braking, then the thermal management improves, but the structural complexity increases
Solution Approach 1:
The wheel incorporates a porous or open-web structure within the disc area, creating natural air circulation channels. This porous design allows air to flow through the wheel structure, providing passive cooling during braking operations without requiring active cooling systems or complex mechanical components.
Data Source
Figure 1~2
Figure 3~6
AI summary
The invention concerns a vehicle wheel (1) obtained from a thermoplastic polymer, said wheel (1) comprising a rim (2), a hub (4) and a disc (3), extending between said rim (2) and said hub (4), said disc (3) comprising a network of ribs (9, 17, 18) inserted between two annular walls (7, 8). The main feature of a wheel (1) according to the invention is that the rim (2), the two annular walls (7, 8) and the network of ribs (9, 17, 18) are produced from a thermoplastic polymer material, and that each rim (9, 17, 18) extends tangentially to the hub (4).