Thermally Deforming Wheel Cover for Drag and Brake Cooling
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Solution Overview
Problem
There is a conflict between optimizing drag resistance and achieving effective brake cooling in vehicle wheels, as existing solutions like multilayer composites with different thermal expansion coefficients are complex, expensive, and prone to faults.
Innovation Solution
A single-piece fiber composite covering element with a wing portion that deforms thermally to open and allow air cooling, featuring a symmetrical upper laminate structure with low thermal expansion and an asymmetrical lower laminate structure for increased thermal expansion in the circumferential direction, enabling self-actuated opening without additional energy sources.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If a single disk-shaped covering element is used to cover the spoke gaps, then the drag resistance is optimized and visual appearance is improved, but the brake cooling action is insufficient
Solution Approach 1:
The covering element incorporates a thermally deformable wing portion that dynamically changes its position based on temperature. At normal temperatures, the wing portion remains closed to minimize drag. When the brake temperature exceeds a defined limit, the thermally responsive material causes the wing portion to deform and open, allowing air to flow through and cool the brake, thus resolving the contradiction between drag reduction and brake cooling.
Solution Approach 2:
The wing portion is made from a thermally responsive material that changes its physical state or shape in response to temperature changes. This parameter change allows the covering element to automatically transition between closed (drag-reducing) and open (cooling) states based on the brake temperature, eliminating the need for external actuators or complex control systems.
2Temperature
If a multilayer composite with different thermal expansion coefficients is used for the wing element, then the thermal deformation function is achieved, but the manufacturing complexity and cost increase
Solution Approach 1:
The patent employs a composite material structure where a thermally responsive material layer is integrated with a structurally stable base material. This composite approach enables the wing portion to deform thermally while maintaining structural integrity, achieving the desired thermal response function without requiring complex multilayer assemblies with precisely matched thermal expansion coefficients.
Solution Approach 2:
The thermal responsiveness is localized to the wing portion rather than the entire covering element. This allows the complex thermally responsive material to be applied only where needed for deformation, while the rest of the covering element can use simpler, more cost-effective materials, thereby reducing overall manufacturing complexity and cost.
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 reduces drag resistance while enabling efficient brake cooling without additional actuators, simplifying manufacturing and reducing weight and costs, while maintaining structural integrity and visual appeal.
Implementation Method 1
the wing element is configured as a multilayer composite consisting of two materials with a different coefficient of thermal expansion
Implementation Method 2
the covering element is configured from a single composite material... the wing portion is deformed solely by way of the influence of heat
Data Source
AI summary
A wheel of a vehicle has a rim, a hub portion and at least two spokes connecting the hub portion to the rim. At least one spoke intermediate space between the spokes is at least partially covered by a single-piece cover element. A wing portion of the cover element is deformed axially away from the wheel when heat is supplied. The cover element is connected directly to the wheel, and the single-piece cover element is formed from a single material.