Composite Wheel Spoke Preform for TPMS Mass Balancing
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Solution Overview
Problem
The addition of a TPMS valve to composite wheels, such as carbon fibre wheels, creates a static mass imbalance due to the unbalanced mass, which existing solutions like wheel weights or material removal cannot effectively address without compromising aesthetics or structural integrity.
Innovation Solution
A shaped preform component made from cured composite fibre material with tailored density is inserted into the fibre layup of the spoke portion of the composite wheel, designed to counterbalance the mass addition, such as a TPMS valve, using a composite composition that matches the thermal and expansion properties of the surrounding material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If wheel weights are added to counterbalance the TPMS valve, then the mass imbalance is corrected, but the visual aesthetics of the wheel are compromised
Solution Approach 1:
The invention extracts the balancing function from separate wheel weights and integrates it directly into the wheel structure through a shaped insert placed in the spoke, eliminating the need for external balancing weights that would compromise aesthetics
Solution Approach 2:
The invention merges the counterbalancing mass with the wheel's structural components by placing a dense insert within the spoke portion, combining the aesthetic wheel surface with the functional balancing mass inside
2Stability of the object's composition
If material is removed from the wheel to counterbalance the mass addition, then the mass imbalance is corrected, but the structural integrity of the composite wheel is compromised
Solution Approach 1:
The invention uses a dense composite insert as a counterweight within the spoke structure to balance the TPMS valve mass, avoiding the need to remove material that would compromise structural integrity
Solution Approach 2:
The invention employs composite materials with varying densities to create a balanced wheel, using a dense insert (higher density than the surrounding composite) to provide counterbalancing mass without removing structural material
3Stability of the object's composition
If a shaped preform with tailored density is used, then the counterbalance mass is achieved, but the manufacturing complexity increases
Solution Approach 1:
The invention changes the density parameter of the insert material to achieve the required counterbalance mass, using a dense composite insert with controlled density to provide precise mass adjustment
Solution Approach 2:
The invention applies local quality by placing a specifically designed dense insert only in the spoke portion where balancing is needed, rather than changing the properties of the entire wheel structure
Data Source
AI summary
A shaped preform component (200A) for a spoke portion (108A) of a composite wheel (100), the shaped preform (200A) comprising: an elongate body (215) configured to be located in a spoke (108) of a composite wheel (100), wherein the shaped preform component (200A) is formed from a cured composite fibre material having a compressibility of <2% volumetric under moulding conditions of 50 bar hydrostatic pressure and a temperature of 60 to 150° C., and wherein the density of the cured composite fibre material is selected to form a counterbalance mass for a mass addition (300) to the composite wheel (100).