Vehicle Wheel Intermediate Layer for Corrosion and Load Management
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Solution Overview
Problem
Wheels composed of multiple materials face issues with electrochemical compatibility leading to contact corrosion and mechanical durability problems at the junction between the rim and wheel center, particularly when using fiber reinforced plastics and metals, which affects the wheel's durability and aesthetic appeal.
Innovation Solution
Incorporating an intermediate layer between the rim and wheel center contact areas to prevent direct contact, which can be designed for load transfer and sealing, using materials like electrically insulating plastics, glass fibers, and metal layers to reduce corrosion and improve stress distribution, and potentially allowing direct contact in certain variants to optimize pressure distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an intermediate layer is added between the rim and wheel center to prevent contact corrosion, then the durability and electrochemical compatibility are improved, but the device complexity and manufacturing steps increase
Solution Approach 1:
An intermediate layer made of electrically insulating material is introduced between the metal wheel center and the fiber reinforced plastic rim to prevent direct electrochemical contact. This intermediary layer acts as a mediator that blocks galvanic corrosion while allowing mechanical load transfer, thereby resolving the contradiction between durability improvement and device complexity by providing a simple yet effective barrier solution.
2Weight of moving object
If different materials are used for rim and wheel center to reduce weight and moment of inertia, then the performance is improved, but the electrochemical compatibility and contact corrosion resistance deteriorate
Solution Approach 1:
The intermediate layer serves as an electrochemical barrier between dissimilar materials (metal wheel center and composite rim), preventing galvanic corrosion while allowing the weight reduction benefits of material differentiation to be realized. This resolves the contradiction by enabling multi-material construction without suffering from the harmful electrochemical interactions.
Solution Approach 2:
The wheel employs a composite construction with a metal wheel center and fiber reinforced plastic rim, creating a hybrid structure that optimizes weight and performance characteristics. The intermediate layer ensures that this composite material approach does not lead to corrosion issues, thereby resolving the contradiction between weight reduction and corrosion resistance.
3Object-affected harmful factors
If the intermediate layer prevents direct contact between rim and wheel center, then corrosion is reduced, but the load transfer efficiency may be affected
Solution Approach 1:
The intermediate layer's mechanical properties are carefully selected and optimized to balance its dual function: maintaining electrical insulation to prevent corrosion while providing sufficient mechanical strength and stiffness for effective load transfer. By adjusting parameters such as material composition, thickness, and structural design, the contradiction between corrosion protection and load transfer efficiency is resolved.
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 intermediate layer effectively prevents contact corrosion and ensures even contact pressure distribution, enhancing the mechanical durability and longevity of the wheel, especially under high torque and cyclic loading conditions, while maintaining aesthetic appeal.
Implementation Method 1
The intermediate layer is designed to prevent direct contact between the at least one first and the at least one second contact area... using materials like electrically insulating plastics
Implementation Method 2
The intermediate layer ensures even contact pressure distribution, enhancing the mechanical durability and longevity of the wheel
Data Source
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AI summary
The invention is directed to a wheel comprising a rim (2) and a wheel center (3) interconnected to the rim (2). The rim (2) comprises at least one first contact area (12) and the wheel center (3) comprises at least one second contact area (13) which in a mounted state are aligned with respect to each other. According to the invention an intermediate layer (22) is arranged between the at least one first and the at least one second contact area (12, 13) preventing at least partially direct contact between the at least one first and the at least one second contact area (12, 13).