Composite Vehicle Wheel Hub Cover for Corrosion and Load Transfer
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Solution Overview
Problem
Wheels made partially from fiber-reinforced plastic materials face challenges in corrosion prevention and stress concentration, particularly at the hub attachment area, which affects efficient load transfer and stress/strain distribution.
Innovation Solution
The introduction of a support cover made from metallic material, integrated into the wheel structure, which includes a three-dimensionally shaped design with channel-like recesses and bushings to enhance load transfer and stress distribution, while preventing corrosion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If a wheel is made partially from fiber-reinforced plastic material, then the weight of the wheel is reduced, but corrosion phenomena occur at the hub attachment area
Solution Approach 1:
A support cover made from corrosion-resistant material (metal or homogeneous material) is introduced as an intermediary component between the fiber-reinforced plastic wheel hub and the fastening means. This support cover prevents direct contact between dissimilar materials, eliminating galvanic corrosion while maintaining the weight benefits of the composite wheel structure.
Solution Approach 2:
The wheel employs a composite structure combining fiber-reinforced plastic material for the wheel body with a support cover made from corrosion-resistant material. This multi-material approach allows the wheel to maintain low weight while protecting the hub attachment area from corrosion through the protective cover layer.
2Device complexity
If fastening means are directly attached to the fiber-reinforced plastic hub, then the device complexity is reduced, but stress concentration occurs at the attachment area
Solution Approach 1:
The support cover serves as a mediator between the fastening means and the fiber-reinforced plastic hub. It distributes the localized fastening forces over a larger area of the hub, preventing stress concentration while adding minimal structural complexity to the attachment system.
Solution Approach 2:
The support cover is strategically positioned only at the hub attachment area where stress concentration occurs, rather than covering the entire wheel. This localized approach addresses the stress distribution problem specifically at the critical attachment zone while maintaining simplicity elsewhere in the wheel structure.
Data Source
AI summary
A wheel (1) for a vehicle and a related method for manufacturing the wheel includes a rim (2) and a wheel center (3). The wheel center includes several spokes (4) extending from a hub (5), with a center opening (6), radially outwards to the rim (2). The hub (5) is made from a fiber-reinforced plastic material and is covered on the outboard side from a three-dimensionally shaped support cover (7) made from metallic material.