Vehicle Wheel Covering Element Composite Layer Design
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Solution Overview
Problem
Existing vehicle wheel designs require a time-consuming adhesive bonding process for fiber-reinforced plastic covering elements, making installation and removal difficult, and limiting the use of alternative joining methods that could compromise the fibers' strength and durability.
Innovation Solution
A vehicle wheel with a covering element composed of two different material layers, a thin metal layer for strength and a thicker plastic layer for ease of manufacturing, where the metal layer is on the outer side and the plastic layer on the inner side, using an insert molding process for joining and a spring ring or clip connection for secure attachment, allowing for easy installation and removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a fiber-reinforced plastic covering element is adhesively bonded to the wheel, then sufficient strength and corrosion protection are achieved, but the installation process becomes time-consuming and removal is difficult
Solution Approach 1:
The covering element is divided into two functional layers: a fiber-reinforced plastic layer for strength and a metal layer for mechanical fastening. This segmentation allows each layer to serve its specific purpose, enabling mechanical attachment through the metal layer while maintaining the strength benefits of fiber-reinforced plastic.
Solution Approach 2:
The covering element uses a composite structure combining fiber-reinforced plastic and metal layers. This composite material approach allows the plastic layer to provide corrosion resistance and strength, while the metal layer enables mechanical fastening through clips or rivets, eliminating the need for time-consuming adhesive bonding.
2Strength
If a fiber-reinforced plastic covering element is used, then sufficient strength is achieved, but alternative joining methods cannot be used without obstructing or destroying the fibers
Solution Approach 1:
The covering element is divided into two functional layers: a fiber-reinforced plastic layer for strength and a metal layer for mechanical fastening. This segmentation allows each layer to serve its specific purpose, enabling mechanical attachment through the metal layer while maintaining the strength benefits of fiber-reinforced plastic.
Solution Approach 2:
The metal layer acts as an intermediary between the fiber-reinforced plastic and the wheel structure. It provides a suitable surface for mechanical fastening methods like clips or rivets, while the fiber-reinforced plastic layer maintains its integrity and strength properties without being directly compromised by the fastening process.
3Object-affected harmful factors
If the spoke intermediate space is fully covered by a covering element, then corrosion protection is improved, but air cooling of the wheel brake is reduced
Solution Approach 1:
The covering element is designed with varying degrees of coverage: it provides corrosion protection in areas where it is installed, while leaving certain regions open for brake cooling. This local differentiation allows the wheel to simultaneously achieve corrosion resistance and effective thermal management of the brake system.
Data Source
AI summary
A wheel of a vehicle, in particular a motor vehicle, has a rim, a hub portion, and at least two spokes connecting the hub portion to the rim. At least one free space between the spokes is covered at least in part by a substantially planar covering element. The covering element is produced from two different material layers.