Formed preform for spoke section of composite wheel

Abstract

A shaped preform component (200A) for a spoke portion (108A) of a composite wheel (100), the shaped preform (200A) comprising: an elongated body (215) configured to be positioned in a spoke (108) of the composite wheel (100), wherein the shaped preform component (200A) is formed of a cured composite fiber material having a compressibility of less than 2% by volume under molding conditions of a hydrostatic pressure of 50 bar and a temperature of 60° C. to 150° C., and wherein the density of the cured composite fiber material is selected to form a counterbalancing mass of a mass addition (300) of the composite wheel (100).

Description

[0001] This application is a divisional application of a patent application with application number 2018800681358, application date August 17, 2018, and invention name “Formed preform for the spoke portion of a composite wheel”.

[0002] Cross-references

[0003] This application claims priority to Australian Provisional Patent Application No. 2017903324 filed on 18 August 2017, the contents of which should be understood to be incorporated herein by this reference. Technical Field

[0004] The present invention generally relates to shaped preforms for the manufacture of spoke portions of composite wheels. The invention is particularly applicable to composite carbon fiber wheels for vehicles and / or aircraft, and it will be convenient to disclose the invention hereinafter in relation to this exemplary application. However, it will be appreciated that the invention is not limited to this application and may be used as a production aid for a variety of composite wheel types. Background Art

[0005] The following discussion of the background of the invention is intended to facilitate understanding of the invention. However, it should be appreciated that the discussion is not an acknowledgement or admission that any of the material referred to was published, known or part of the common general knowledge as at the priority date of the application.

[0006] A tire pressure monitoring system (TPMS) allows real-time monitoring of the air pressure in a pneumatic tire mounted on a vehicle wheel. A TPMS system includes a TPMS valve mounted in a vehicle wheel. However, adding a TPMS valve to a vehicle can create a static mass imbalance in the entire wheel assembly due to the additional unbalanced mass that the valve may add on one side of the wheel.

[0007] This imbalance can be addressed by adding adhesive or mechanically fastened wheel weights to the wheel (usually around the rim of the wheel), or by selectively removing material at locations on the wheel to counterbalance the mass addition in wheels made of isotropic materials (e.g., metal or metal alloy wheels). However, the use of wheel weights may destroy the desired visual aesthetics of certain wheel configurations. Furthermore, balancing the wheel by material removal is not a viable solution for composite wheels such as carbon fiber wheels, as the removal of material may compromise the structural integrity of the composite wheel.

[0008] It would therefore be desirable to provide a new equalizing and / or balancing arrangement for a composite wheel that can be configured to counteract any unbalanced mass additions made to the composite wheel. Summary of the invention

[0009] The present invention provides a pre-formed prefabricated insert for assembly to a fiber layup of a spoke portion (forming part of a face portion) of a composite wheel, preferably a carbon fiber wheel for a vehicle.

[0010] The present invention provides, in a first aspect, a shaped preform component for a spoke portion of a composite wheel, the shaped preform component comprising:

[0011] an elongated body configured to be positioned within a spoke of a composite wheel,

[0012] wherein the shaped preform part is formed from a cured composite fiber material having a compressibility of less than 2% by volume under forming conditions of a hydrostatic pressure of 50 bar and a temperature of 60° C. to 200° C.,

[0013] and wherein the density of the cured composite fiber material is selected to form a counterbalancing mass of the mass addition of the composite wheel.

[0014] In an embodiment, the mass addition comprises an unbalanced mass addition of the wheel, preferably a non-composite, non-carbon fiber mass addition. In an exemplary embodiment, the mass addition comprises a valve, preferably a tire pressure monitoring valve.

[0015] It should be understood that the term "composite" herein means any type of composite material including fibers, whether cured or uncured, regardless of whether the structure is layered. In addition, cured or uncured preforms and pre-consolidated preforms are important subgroups of composite materials and bodies.

[0016] It should also be understood that the term "cured" in "cured composite fibre material" means that the composite fibre material has undergone at least a partial curing process to harden, cure or solidify the curable matrix material in the composite fibre material.

[0017] Composite wheels (e.g., as taught in International Patent Publication No. 2014 / 165895A9 by the applicant of the present application) generally include two main parts, namely a rim portion and a face portion. The rim portion includes an annular structure configured to receive and seat a tire. The face portion includes a hub for securing the wheel to a vehicle, and a spoke connection structure including a series of spoke portions extending between the hub and the rim and interconnecting the hub and the rim. Transverse, vertical and torsional loads are transmitted to the rim portion of the wheel through the tire, which then generates bending and torsional stresses in the connection structure.

[0018] The spoke portion of the applicant's composite wheel has previously been incorporated with a shaped foam preform. This conventional shaped preform is composed of an isotropic foam material formed into a rigid or semi-rigid foam body. The density of such foam preforms cannot be easily changed without adding additional weight inserts or portions into or around the composed foam material. In addition, these foam preforms are typically at least semi-compressible and have surfaces formed of a material that is limited in compressibility compared to the surrounding composite material.

[0019] The present invention provides a shaped preform that can be used in the layup and molding process for forming the spoke portion of a composite wheel and can be formed with a customized density. Therefore, the mass of the shaped preform can be designed to suit the mass requirements of a specific one or more spokes in the composite wheel. The customized density is achieved by varying the composite material components of the preform (as described in more detail below) and more particularly the filler materials used in the composite material components. The composite material components can then be selected to provide a density and therefore a mass suitable to counterbalance the mass additions that make up the composite wheel. One specific application is as a counterbalance for a TPMS valve assembled into a composite wheel.

[0020] The shaped preform according to the invention is intended to form a direct replacement for conventional foam inserts for layup of spoke portions of composite wheels. Therefore, no special considerations for wheel manufacturing are required when using this new insert, since it becomes a direct replacement for conventional foam core inserts in the wheel manufacturing process (layup, shaping, etc.).

[0021] The shaped preform part can occupy any amount of the space of the spokes of the composite wheel. In some embodiments, the shaped preform part is designed to occupy the entire volume. In other embodiments, the shaped preform part can occupy a portion of the core volume of the spoke. In the case where the shaped preform occupies a portion of the volume of the spoke, another preform, such as a foam part, can be used in conjunction with the present invention to fill out the volume.

[0022] The spoke inserts are formed of a composite material to allow for complex molding and provide a match to the composite component of the composite wheel, thereby giving the preform similar thermal and expansion characteristics to the surrounding composite layup material of the composite wheel. In addition, the use of composite materials avoids the use of metallic materials, thereby avoiding distortion of X-ray inspection images during manufacturing quality assurance testing. The composite component also provides the ability to adjust the mechanical properties of the spoke insert for different applications. More specifically, the density of the spoke insert can be varied with the adjustment of the filler material to provide a desired mass suitable for counterbalancing the mass addition of the composite wheel (the shaped preform is expected to form a part of this composite wheel). In addition, the spoke insert is a better match for the spoke structure in terms of thermal expansion coefficient, thereby exerting less stress on the composite material when heated. Excessive stress can cause the preform to detach from the surrounding carbon fiber material.

[0023] The shaped preform may be formed from any number of different materials, including a curable matrix material or may be bounded by a curable matrix material, such as a resin, to form a cured composite fiber material. Likewise, specific material selections are made for the components used in the shaped preform to provide a specific customized density for the shaped preform. Depending on the application, the density may be customized to be between 0.3 g / cm 3 Up to 3.0g / cm 3 Between, preferably between 0.3g / cm 3 Up to 2.0g / cm 3 and more preferably from 0.4 g / cm 3 To 1.8g / cm 3 In some embodiments, the density of the shaped preform is from 0.5 g / cm 3 To 1.5g / cm 3 In some embodiments, the density of the formed preform is from 0.4 g / cm 3 To 1.2g / cm 3 In some embodiments, the density of the formed preform is from 0.8 g / cm 3 To 1.6g / cm 3 In some embodiments, the density of the formed preform is from 0.4 g / cm 3 To 1.5g / cm 3 In some embodiments, the density of the formed preform is from 1.0 g / cm 3 To 1.8g / cm 3 In some embodiments, the density of the formed preform is from 0.4 g / cm 3 To 1.0g / cm 3 The components are usually selected as follows:

[0024] In some embodiments, the shaped preform is formed of resin (neat resin) or is formed substantially only of resin.

[0025] In some embodiments, the shaped preform is formed from at least one of: a customized fiber-implanted ply or preform; one or more single-fiber oriented plies (unidirectional); one or more multi-directional fiber plies (e.g., a stitched, non-crimped fabric); or a fiber patch implanted (FPP) preform, such as CEVOTECH technology.

[0026] In some embodiments, the shaped preform is formed from: at least one layer of nonwoven isotropic or anisotropic fibers, e.g. Recycled carbon fiber nonwoven fabric; isotropic fiber arrangement; orthotropic fiber arrangement; filler; glass microspheres, preferably hollow glass microspheres; ceramic microspheres; barium sulfate; hydrophobic fumed silica; epoxy resin / hardener; phenolic resin; milled carbon fiber; pulverized carbon fiber (e.g., chopped or chopped carbon fiber); or a combination thereof.

[0027] In a preferred embodiment, the shaped preform part is formed from at least one of the following:

[0028] (i) a mixture of resin, milled carbon fibers and hollow glass microspheres;

[0029] (ii) a mixture of resin, comminuted carbon fibers and hollow glass microspheres;

[0030] (iii) a mixture of resin and hollow glass microspheres;

[0031] (iv) a mixture of resin and milled carbon fibers;

[0032] (v) a mixture of resin and pulverized carbon fibers;

[0033] (vi) a mixture of resin, milled carbon fibers and solid ceramic microspheres;

[0034] (vii) a mixture of resin, crushed carbon fibers and solid ceramic microspheres;

[0035] (viii) a mixture of a resin and solid ceramic microspheres; or

[0036] (ix) Substantially only resin.

[0037] In exemplary embodiments, the shaped preform part is formed from at least one of:

[0038] (x) a mixture of resin, milled carbon fibers and hollow glass microspheres;

[0039] (xi) a mixture of resin and hollow glass microspheres;

[0040] (xii) A mixture of resin and milled carbon fibers.

[0041] In the above components (i) to (xii), the resin preferably comprises a mixture of a resin and a resin hardener. In addition, the component may optionally further comprise from 1 wt% (mass percentage) to 5 wt%, preferably 1 wt% to 2 wt% of hydrophobic fumed silica. In other embodiments, the component may optionally comprise from 2 wt% to 5 wt%, preferably 2 wt% to 3 wt% of hydrophobic fumed silica.

[0042] It should be appreciated that any suitable milled carbon fiber may be used. In some embodiments, the milled carbon fiber has a length of less than 500 μm, preferably less than 100 μm. For example, milled carbon fiber having a length of 100 μm, such as Carbiso TM MF. However, it will be appreciated that any brand of milled carbon fiber is suitable. Other fiber types of similar length may be used.

[0043] In other embodiments, comminuted carbon fibers, such as chopped carbon fibers, may be used. The comminuted carbon fibers may have a length of less than 20 mm, preferably less than 15 mm, more preferably between 1 mm and 15 mm. For example, comminuted carbon fibers having a length of about 12 mm may be used. Other fiber types of similar lengths may be used.

[0044] The preferred material is a mixture of mixed resin & hardener, hollow glass microspheres, milled carbon fiber and hydrophobic fumed silica mixed in the following ratios, the masses mixed in these ratios are sufficient to offset the proposed imbalance in the wheel assembly caused by the mass addition. In some embodiments, the component mixing ratio (may be in parts by mass):

[0045]

[0046] The pulverized carbon fibers of Option G preferably include chopped carbon fibers having a length of 12 mm.

[0047] Each of the above options (Options A to G) may further include 1 wt% to 5 wt%, preferably 1 wt% to 2 wt% of hydrophobic fumed silica.

[0048] While the above options (A through G) provide specific examples of components and resulting theoretical densities, it should be appreciated that other and alternative mixing ratios and materials may also provide the desired custom density.

[0049] In an exemplary embodiment, the shaped preform part is formed of a material including a mixture of mixed resin: milled carbon fiber: hollow glass microspheres in a ratio (mass parts) of 3.75:1:0.56. In an embodiment, the ratio (mass parts) of mixed resin: milled carbon fiber is from 2.5:1 to 5:1, preferably between 3:1 and 4:1. In an embodiment, the ratio (mass parts) of milled carbon fiber: hollow glass microspheres is from 1:0.4 to 1:0.7, preferably between 1:0.5 and 1:0.6.

[0050] Various suitable hollow glass microspheres can be used in the components of the formed preform. The hollow glass microspheres preferably include hollow glass spheres with thin walls. The hollow glass microspheres can be formed from a variety of glass materials, including (but not limited to) soda-lime-borate silicate glass. The softening temperature of the hollow glass microspheres is preferably at least 500°C, more preferably at least 600°C, and more preferably about 600°C. The size of the hollow glass microspheres is preferably from 10μm to 200μm, more preferably from 18μm to 65μm. In addition, the target crushing strength (90% survival rate) of the hollow glass microspheres is preferably from 250psi to 28000psi, more preferably from 250psi to 6000psi, and more preferably from 250psi to 3000psi. In addition, the true density of the hollow glass microspheres is preferably 0.125 g / cc to 0.60 g / cc, more preferably from 0.125 g / cc to 0.4 g / cc, and even more preferably from 0.125 g / cc to 0.28 g / cc. In an exemplary embodiment, the hollow glass microspheres include 3M S28HS glass bubbles (available from 3M Advanced Material Division), which have an average diameter of 30 μm and a crush strength (90% survival rate by volume) of 3000 psi and a true density of 0.28 g / cc. However, it should be appreciated that other similar microspheres may also be used. For example, alternative hollow microspheres may be used, such as 3M K1 bubbles with a target crush strength of 250 psi and a true density of 0.125 g / cc, or 3M IM30K (or the like) with a crush strength of 28000 psi and a true density of 0.60 g / cc.

[0051] Where fiber-based materials are used, the shaped preform may be formed from at least one of the following materials: a fiber layer, a fiber ply, a prepreg, a semipreg, a woven or non-woven fabric, a mat, a preform, a preconsolidated preform, individual or grouped fibers, a tow, a tow preg.

[0052] It is understood that prepreg refers to a collection of substantially or completely impregnated fibers, fiber tows, woven or nonwoven fabrics, etc. Similarly, it is understood that semipreg refers to a collection of partially impregnated fibers or fiber tows. Partial impregnation provides enhanced removal of gases through or along the dry fibers during consolidation and / or curing. An example of a semipreg is a partially impregnated fiber layer.

[0053] It is understood that a woven or nonwoven fabric is a collection of individual fibers or fiber tows that are substantially dry (i.e., not impregnated with a matrix material such as a resin). It is also understood that a fiber tow is a bundle of a large number of individual fibers (e.g., 1,000, 10,000, or 100,000 fibers). A tow prep is an at least partially impregnated fiber tow.

[0054] A variety of fibers can be used in the present invention, including but not limited to fibers selected from the group consisting of: carbon fibers, glass fibers, aramid fibers, synthetic fibers (such as acrylic, polyester, PAN, PET, PE, PP or PBO fibers, etc.), biological fibers (such as hemp, jute, cellulose fibers, etc.), mineral fibers (e.g., rock wool (Rockwool)), metal fibers (e.g., steel, aluminum, brass, copper, etc.), boron fibers or any combination thereof. In a preferred embodiment, the fibers include carbon fibers. The fibers can be provided in any desired orientation in the transition region, such as unidirectional, biaxial or random or a combination of these. However, the fibers are preferably oriented to reduce stress between composite components and to enhance areas of the final structure that will be subjected to higher stresses during use. The orientation of the fibers can be the same or different in all layers containing fibers in the transition region. For example, if stress analysis suggests multiaxial fiber orientation, one or more layers of fibers can be oriented in another manner different from other layers. However, in other embodiments, the fibers can be oriented in substantially the same manner in all fiber layers.

[0055] It will be appreciated that the shaped preform component should be formed of a material that ensures minimal volume change when used to form the face portion of the composite wheel. Where the material comprises a fiber arrangement (e.g., an isotropic fiber arrangement), a fiber layer, a fiber ply, a prepreg, a semipreg, a woven or non-woven fabric, a mat, a preform, a preconsolidated preform, individual or grouped fibers, tows, or tow pregs, the material is preferably treated to provide the necessary compressibility and thereby provide minimal volume change in subsequent processing steps.

[0056] The cured composite fiber material provides structural rigidity and / or robustness to the preform, which can be used to maintain the designed configuration of the preform in the shape and form of the entire composite wheel. The shaped preform is designed to have limited compressibility so as to provide appropriate volume and minimal volume changes during layup and molding of the face portion of the composite wheel. Therefore, the use of the shaped preform of the present invention in the layup of the spoke portion of the composite wheel minimizes and more preferably avoids undesirable dimensional and volume changes that may damage the structure of the molded composite wheel. It should be appreciated that the compressibility of the shaped preform is measured in % by volume under molding conditions where the hydrostatic pressure (e.g., during resin injection) is 50 bar and the process temperature range during the resin molding process (such as a resin transfer molding (RTM) process) is 60°C to 200°C.

[0057] The process temperature during the molding condition may vary depending on the preferred injection and curing temperatures. The preferred process temperature is about 120°C (typically 120°C + / - 3°C). However, the process temperature may be in the range of 60°C to 180°C, preferably 60°C to 150°C, more preferably 60°C to 140°C. In an embodiment, the process temperature is 100°C to 200°C, preferably 100°C to 150°C, more preferably 100°C to 130°C. In an embodiment, the process temperature is 110°C to 150°C, preferably 110°C to 130°C.

[0058] The mechanical properties of the shaped preform of the present invention can be tailored to the desired application. As described above, the compressibility of the composite fiber body must be less than 2% by volume under the molding condition of a hydrostatic pressure of 50 bar. In some embodiments, the compressibility of the shaped preform is less than 1.5% by volume, preferably less than 1% by volume under the molding condition of a hydrostatic pressure of 50 bar. The process temperature of the molding condition is the same as described above.

[0059] Other mechanical properties of the shaped preform of interest include:

[0060] Tensile strength - which is preferably between 20 MPa and 80 MPa, more preferably from 20 MPa to 60 MPa; and

[0061] Stiffness - It is preferably from 1.5 GPa to 30 GPa, preferably from 5 GPa to 30 GPa, more preferably from 8 GPa to 30 GPa, and even more preferably from 10 GPa to 25 GPa. In some embodiments, the stiffness is from 1.5 GPa to 10 GPa. In other embodiments, the stiffness is from 8 GPa to 25 GPa. In some embodiments, the stiffness is from 2 GPa to 30 GPa, preferably from 10 GPa to 25 GPa.

[0062] The surface of the shaped preform preferably has a rough surface with a roughness of at least Ra=0.2 μm. This surface roughness helps the shaped preform to bond with the surrounding material of the hub portion when placed in the fiber layup of the hub portion of the composite wheel. The rough surface can be formed by any suitable means. In some embodiments, the rough surface includes a chemically etched surface, a mechanically abraded surface, or a specially textured surface.

[0063] The thermal expansion characteristics of the shaped preform are preferably designed to be similar, preferably substantially matching, to the thermal expansion characteristics of the entire composite material of the face portion of the composite wheel in which the shaped preform is configured to be included. Similar or substantially matching thermal expansion characteristics of the shaped preform and the surrounding material (typically a laminate) avoid material damage such as delamination at the surface of the shaped preform during post-curing processes. Thus, the thermal properties (and mechanical properties) of the shaped preform match the surrounding wheel structure.

[0064] The method of forming a shaped preform generally involves the following general steps:

[0065] laying or otherwise forming a desired shape of a shaped preform with a selected composite fiber material in a co-forming mold;

[0066] providing a matrix material in contact with the layup material in the mold to form a matrix material lead-in; and

[0067] The matrix lead-in is cured.

[0068] The layer material is usually poured with a matrix material so that the matrix material penetrates the material. Therefore, the shaped preform usually further includes a curable matrix material surrounding the constituent parts of the shaped preform. Once formed and formed into a shaped preform, the shaped preform includes a matrix material that bonds the fibers to other constituent materials. During the layering (preparation until the moment before the consolidation and / or solidification, curing, etc. of the matrix material), it is not necessary to include a matrix material in the layer including fibers (e.g., prepreg or semipreg) or between the layers including fibers. However, the matrix material should form a continuous matrix after solidification occurs. Suitable matrix materials can be selected from (but not limited to) resins based on unsaturated polyesters, polyurethanes, polyvinyl esters, and epoxy resins, allowing the molding of shaped preforms with complex geometric structures.

[0069] It should be appreciated that the curing step can be controlled to provide desired mechanical properties, including stiffness and compressibility. The mechanical properties of the shaped preform can be designed to suit a particular application. These properties can be altered by selecting the component materials from which the shaped preform is formed, the matrix material, the amount of matrix material injected or contained therein, and the curing schedule (curing time, temperature, whether the object is fully cured). In some cases, it is desirable to stop the curing process before the shaped preform is fully cured in order to produce surface properties that aid in the adhesion of subsequent layup materials when used for layup of the face portion of a composite wheel.

[0070] Advantageously, the surface of the shaped preform is preferably designed to adhere to the remaining materials and structures used to form the composite wheel. In an embodiment, the surface of the shaped preform is configured to facilitate adhesion of carbon fibers or materials including carbon fibers. As described above, the surface of the shaped preform preferably has a rough surface with a roughness of at least Ra=0.2 μm. The rough surface can be formed by any suitable means. In some embodiments, the rough surface includes a chemically etched surface, a mechanically abraded surface, or a mechanically characterized surface.

[0071] The surface characteristics of the shaped preform can be modified by changing the curing characteristics and scheme of the shaped preform. In some embodiments, the shaped preform includes an incomplete or incompletely cured preform. However, it must also be appreciated that the shaped preform is cured and otherwise processed to provide a selected compressibility that can provide minimal volume changes in subsequent fiber layup and molding processing steps. The filler material and resin can preferably be injected into the mold before curing.

[0072] The shaped preform is typically formed with a designed shape and geometry that provides a basis for forming the geometry (in some cases a complex geometry) of the spoke portion of the desired composite wheel. The spokes or spoke portions of the composite wheel typically extend along a centerline extending radially from the central axis of the composite wheel. The shaped preform follows this shape and is typically formed into an elongated body configured to extend along a centerline extending radially from the central axis of the composite wheel.

[0073] The spoke portion of the composite wheel may have any suitable configuration. In an embodiment, the spoke portion includes a generally cuboid or rectangular box-shaped body. The body preferably includes at least two arms extending laterally outward from one end of the elongated body, preferably having end surfaces configured to complement the contour and shape of an adjacent or proximate surface constituting a rim portion of the composite wheel. The body also preferably includes at least one L-shaped end portion extending axially outward from one end of the elongated body, preferably having an end surface configured to complement the contour and shape of an adjacent or proximate surface constituting a rim portion of the composite wheel.

[0074] The shaped preform may additionally include a number of features designed to facilitate the subsequent formation and layup of the face portion of the composite wheel. These features include (but are not limited to):

[0075] The fiber plies maintain the structure;

[0076] Guide lines that visually indicate where the edge of the ply should be located; or

[0077] Holding / manipulating structure for optimizing the handling of shaped preforms.

[0078] In a second aspect, the present invention provides a method of forming a face portion of a composite fiber wheel, comprising:

[0079] positioning a shaped preform according to any one of the preceding claims in a spoke portion of a fiber layup of a face portion of a composite wheel at a position suitable for balancing the mass addition about a central axis of the face portion of the composite wheel; and

[0080] Composite fiber elements are laid around the shaped preform, thereby forming a preformed structure of the spoke portion of the composite fiber wheel.

[0081] The shaped preform may be placed in any position in one or more spoke portions of the face portion layup of composite fibers that is suitable for balancing the mass addition about the central axis of the face portion of the composite wheel. Typically, this position will be a position that is substantially radially opposite to the position of the mass addition. However, in some embodiments, the shaped preform may be designed to be positioned on the same side of the mass addition that is in line about the central axis. For example, where the mass addition comprises a valve, such as a TPMS valve, the shaped preform is located in a spoke portion that is positioned substantially radially opposite to the valve position on the composite wheel.

[0082] Preferably, the fibers and fiber elements of the fiber plies of the shaped preform, the face portion, are injected with a matrix material and / or impregnated with a matrix material, and then cured, solidified, etc. Therefore, the face portion preferably further includes a matrix material surrounding the fiber plies and containing the fibers and fiber elements. Any suitable matrix material can be used. In some embodiments, a resin is used. The resin is preferably based on unsaturated polyesters, polyurethanes, polyvinyl esters, epoxy resins, thermoplastics, similar compounds or combinations thereof. In a preferred embodiment, the resin is based on epoxy resin. In other embodiments, the matrix material includes a metal matrix that forms a composite metal matrix with the fibers when solidified. The metal matrix material is preferably selected from aluminum, magnesium, titanium, iron and combinations thereof, alloy mixtures. Once molded and formed into a composite wheel, the face portion includes matrix materials such as resins, metals and fibers.

[0083] The fiber layup of the face portion is preferably injected and / or impregnated with a curable matrix material and then cured and / or solidified. Therefore, the method preferably further comprises the following steps:

[0084] providing a base material in contact with the preformed structure of the facial portion; and

[0085] Allow the facial part to solidify.

[0086] Preferably, the surface of the shaped preform is activated to enable it to bond with the surrounding material when the matrix material is injected and / or impregnated. Activation is typically a surface marking process, which can be achieved, for example, by chemical etching, mechanical abrasion or the like.

[0087] The shaped preform is preferably formed integrally with the composite wheel. In addition, the composite wheel is preferably formed as a one-piece body. This typically involves injecting and / or impregnating the matrix material simultaneously and then allowing each portion of the composite wheel to cure, solidify, etc. In such an embodiment, each of the rim portion and the face portion is preferably at least partially uncured in preparation for the connecting portion. The connecting portion is preferably formed integrally with the composite wheel. In such an embodiment, the method further comprises the following steps:

[0088] simultaneously providing a base material in contact with each of the rim portion and the face portion of the wheel; and

[0089] The rim portion and the face portion of the wheel are cured simultaneously.

[0090] It should be appreciated that solidification of the base material and associated parts (such as face portions, rim portions, integral composite wheels, or the like) involves curing, setting, drying, or the like.

[0091] Where the matrix material comprises a resin, a variety of resin delivery systems may be used with the method of the second aspect. In some embodiments, at least a portion of the resin is provided by resin infusion and / or resin transfer molding and / or vacuum assisted resin transfer molding.

[0092] The fibers and fiber elements of the fiber layup of the face portion of the composite wheel preferably include carbon fiber fibers. However, it should also be appreciated that a wide variety of fibers can be used in the present invention, including but not limited to fibers selected from the group consisting of: carbon fiber, glass fiber, aramid fiber, synthetic fiber (such as acrylic, polyester, PAN, PET, PE, PP or PBO fiber, etc.), biological fiber (such as hemp, jute, cellulose fiber, etc.), mineral fiber (e.g., rock wool), etc.), metal fiber (e.g., steel, aluminum, brass, copper, etc.), boron fiber or any combination thereof. In a preferred embodiment, the fiber comprises carbon fiber. The fiber can be provided in any desired orientation in the transition region, such as unidirectional, biaxial or random or a combination of these. However, the fiber is preferably oriented to reduce stress between composite components and to enhance the area of ​​the final structure that will be subjected to higher stress during use. In all layers containing fibers in the transition region, the orientation of the fibers may be the same or may be different. For example, if the stress analysis suggests a multiaxial fiber orientation, one or more layers of fibers may be oriented in another manner different from other layers. However, in other embodiments, the fibers may be oriented in substantially the same manner in all fiber layers.

[0093] The fiber element may be provided in any suitable form, including prepregs, semipregs, woven or nonwoven fabrics, mats, preforms, preconsolidated preforms, individual or grouped fibers, tows, tow pregs, etc. In an embodiment, the fiber element is provided as at least one fabric sheet, preferably a multiaxial fabric. During the layup (preparation until the moment before consolidation and / or solidification, curing, etc. of the matrix material), the matrix material does not need to be included in the layer comprising the fibers (e.g., prepregs or semipregs) or between the layers comprising the fibers. However, the matrix material should form a continuous matrix after solidification occurs.

[0094] The face portion can be formed from a custom fiber preform having a desired shape and fiber orientation, including the shaped preform of the present invention. The custom fiber preform is formed to have a desired shape and fiber orientation. It should be understood that the preform is a composite material including fibers. In some cases, the preform may also include an uncured matrix material such as a resin. Some preforms may include essentially dry fibers without a matrix material. A binder may be used to help hold the plies together before the matrix material is injected.

[0095] A third aspect of the invention provides a composite wheel comprising a shaped preform according to the first aspect of the invention. In some embodiments, the composite wheel is formed around a central wheel axis.

[0096] A further aspect of the invention provides a shaped preform component for a spoke portion of a composite wheel, the shaped preform component comprising:

[0097] an elongated body configured to be positioned in a spoke of a composite wheel,

[0098] wherein the shaped preform part is formed from a cured composite fiber material having a compressibility of less than 2% by volume under forming conditions of a hydrostatic pressure of 50 bar and a temperature of 60° C. to 150° C.,

[0099] And wherein the density of the cured composite fiber material is selected to be between 0.3 g / cm 3 Up to 3g / cm 3 and preferably from 0.4 g / cm 3 Up to 2g / cm 3 .

[0100] In some embodiments, the density of the cured composite fiber material is selected to be between 0.3 g / cm 3 Up to 2g / cm 3 and more preferably from 0.4 g / cm 3 Up to 1.8g / cm 3 In some embodiments, the density of the shaped preform is from 0.5 g / cm 3 Up to 1.5g / cm 3 In some embodiments, the density of the shaped preform is from 0.4 g / cm 3 Up to 1.2g / cm 3 In some embodiments, the density of the shaped preform is from 0.8 g / cm 3 Up to 1.6g / cm 3 In some embodiments, the density of the shaped preform is from 0.4 g / cm 3 Up to 1.5g / cm 3 In some embodiments, the density of the shaped preform is from 1.0 g / cm 3 Up to 1.8g / cm 3 In some embodiments, the density of the shaped preform is from 0.4 g / cm 3 Up to 1.0g / cm 3 .

[0101] It will be appreciated that this further aspect of the invention may incorporate all features discussed above in relation to the first aspect of the invention.

[0102] The present invention preferably provides a shaped preformed insert for assembly into a fiber layup of a spoke portion of a carbon fiber wheel for a vehicle such as a car, truck, airplane, bus, etc. The shaped preformed insert may also be used as a reinforcement fiber layup aid for forming a spoke portion of a composite wheel. BRIEF DESCRIPTION OF THE DRAWINGS

[0103] The present invention will now be described with reference to the figures of the accompanying drawings which show certain preferred embodiments of the invention, in which:

[0104] Figure 1 is a perspective view of a composite wheel including a connection portion between a face portion and a rim portion thereof according to one embodiment of the present invention.

[0105] Figure 2 yes Figure 1 A more detailed view of the rim to face connection area of ​​the composite wheel shown.

[0106] Figure 3 Provided Figure 1 and Figure 2 A front cross-sectional view of a composite wheel is shown.

[0107] Figure 4 An isometric top view of a shaped preform according to an embodiment of the present invention is provided. DETAILED DESCRIPTION

[0108] See first Figure 1 , shows a perspective view of a composite wheel 100 that has been formed and integrally includes a shaped preform 200A of the present invention. The applicant of the present application has developed the composite wheel 100 shown as a composite wheel formed as a one-piece body. The general process of manufacturing the composite wheel 100 is described in International Patent Publication WO2010 / 024495A1, the contents of which should be understood to be incorporated herein by this reference.

[0109] The composite wheel 100 shown comprises two main parts:

[0110] A) a rim portion 102 comprising an annular structure to which a tire (not shown) is mounted; and

[0111] B). Face portion 104 including a circular hub 106 and a series of spokes 108. Hub 106 includes a central hole 107 and may also include a plurality of fastening holes configured to receive fastening bolts (not shown) for securing the wheel to a vehicle wheel frame (not shown) or a center-lock wheel fastening formation (also not shown) with associated holes in hub 106. Spokes 108 include elongated arms connected to hub 106 at one end and to rim portion 102 at the other end.

[0112] As described in International Patent Publication WO2010 / 024495A1, the manufacture of such a one-piece composite wheel 100 requires the use of separate rim portion molds (not shown) and face portion molds (not shown). In use, the rim portion 102 is formed by laying a first set of fibers (typically embodied as a reinforcing fabric placed in the rim portion mold), and the face portion 104 is formed by separately laying a second set of fibers (typically embodied as a reinforcing fabric placed in the face portion mold). The rim portion mold includes an inner barrel mold and an outer cylindrical mold. The reinforcing fabrics from the rim portion mold and the face portion mold are then assembled together in a combined mold with the separate parts interconnected at the connection point 110. A final molding process is then performed in which a matrix material such as a resin is injected and / or poured into the reinforcement in the form of a monolithic wheel to produce a molded one-piece wheel 100.

[0113] The shape and configuration of the face portion 104 may be formed by layup in the face portion mold. Formed inserts may be used in various portions of the face mold to assist in forming features of the face portion. An example is the applicant's co-pending patent application (claiming priority to provisional patent application No. 2017903324), which teaches the use of formed preforms to assist in forming the hub portion 106 of the composite wheel 100. In addition, the hub portion 106 may be formed by layup in the face portion mold. Figure 2 The shaped foam insert 200 shown in Figure 1 constructs the spoke portion 108 of the composite wheel 100. The foam insert 200 is composed of a dense foam material such as polyurethane foam, polymethacrylamide, syntactic material, etc., and is formed into the desired spoke shape prior to layup of the face portion. The foam insert can be used in the spoke because the load transfer between the hub portion 106 and the rim portion 102 can be made through the wall of the spoke 108 by designing the fiber layups and the fiber orientation in these layups. Thus, the foam insert acts as a lightweight core fill material around which the fiber layups can be formed.

[0114] The shaped preform 200A ( Figure 2 , Figure 3 and Figure 4 ) is designed as a direct replacement for a conventional foam spoke insert 200. Thus, in this manner, no special considerations are required in wheel manufacturing when using this new shaped preform, as it becomes a direct replacement for a conventional foam core insert in existing manufacturing processes. Just like conventional foam inserts, the composite shaped preform 200 facilitates layup, wherein the composite shaped preform 200 is positioned in the spoke portion 108 in the mold and a layup is formed around the preform 200.

[0115] It should be appreciated that one or more of the spokes 108 of the composite wheel 100 may include a shaped preform 200A. In some embodiments, only a selected number (typically one or two) of the spoke portions 108 include a shaped preform 200A. The remaining spokes include conventional foam inserts. In some embodiments, all spokes include a shaped preform 200A. In these embodiments, the composition and therefore the density of each shaped preform 200A may be designed and customized for the specific requirements of each spoke. The composite wheel 100 may then be balanced by the density design of the spoke portions 108. However, it should be understood that multiple foam inserts 200 and shaped preforms 200A may be mixed and matched to suit a particular application and / or economy.

[0116] exist Figure 3 In the preferred embodiment shown, a single spoke 108A of the composite wheel 100 may include a shaped preform 200A. The remaining spokes include conventional foam inserts 200. This spoke is generally located at a location radially opposite to where the TPMS valve 300 is mounted on the composite wheel 100. As will be explained in more detail below, the density of the shaped preform 200A may then be designed to provide a counterweight to the TPMS valve 300 mounted on the composite wheel 100.

[0117] However, although the preform 200A is formed Figure 2 and Figure 3 108A, but in other embodiments may occupy only a portion of the core volume of spoke 108A for counterbalancing functions. In the case where the shaped preform part occupies a portion of the volume of the spoke, another preform (e.g., a foam part) may be used in conjunction with the present invention to fill out the volume.

[0118] Figure 3 and Figure 4 Shown for use such as Figure 1 and Figure 2An example of a layup and formed preform insert 200A of a face portion 104 of a composite wheel 100 is shown. The shaped preform 200A shown is used to provide the shape and configuration of the spoke 108 connection portion of the face portion 104. Therefore, the shaped preform 200A shown includes an elongated body 215 extending between the hub 106 and the rim 102 of the composite wheel 100. The shaped preform 200A has a generally cuboid or rectangular box-shaped body that defines an axis extending between the hub 106 and the rim 102. The hub end 220 includes two arms 222 that extend laterally outward from the end 220 to form a T-shaped connection portion for engaging with the outer side of the hub 106. The hub 106 has a generally circular outer configuration. Therefore, the arms 222 and the end surface have a curved outer side 223 that substantially matches the circumferential curve of the outer side of the hub 106. The rim end 225 includes an axial flange / leg 227 that extends downward (relative to the Figure 4 The flange 227 is configured to extend along the rim 102 toward the mounting side or inner side 111 ( Figure 1 The outer side surface 226 of the end surface of the rim end 225 is contoured to substantially match the curve of the outer side surface of the rim 102 .

[0119] Nonetheless, it should be appreciated that the exact geometric configuration of the shaped preform 200 depends on the desired configuration of the hub 106 of the composite wheel 200 and the desired shape and configuration of the spoke portions 108. For example, the number of spokes 108 may vary, thereby affecting the shape and size of each spoke portion 108. The desired configuration of each spoke portion 108 may vary for aesthetic purposes and may include desired patterns, markings, and / or geometries, such as desired complex geometries.

[0120] Although not shown, the shaped preform 200 may be shaped / configured to include a number of additional features designed to assist in the subsequent formation and layup of the face portion of the composite wheel. These features include (but are not limited to): fiber ply retention structures such as steps, recesses, slots, etc.; guide lines that visually indicate where the ply edge should be located; or retention / handling structures such as recesses, flanges, holes, ribs, hooks, protrusions, etc. for optimizing the handling of the shaped preform.

[0121] The shaped preform 200 is designed to have a customized density that is selected to counterbalance the mass addition of the composite wheel 100. A specific example is as a TPMS valve 300 ( Figure 1 )'s counterweight.

[0122] In order to act as a counterweight to the added mass, the mass and moment imbalance (moment and mass balance about the center XX of the composite wheel 100) created by the mass addition must be determined. The shaped preform 200 is then designed to be positioned at a location that counterbalances the mass and moment of the mass addition, e.g., positioned at a location about the center axis XX of the face portion 104 of the composite wheel 100 that is substantially radially opposite to the location of the mass addition. The mass, and therefore the density, of the shaped preform 200 is then tailored to provide the correct counterbalance mass about the center axis XX relative to the mass addition for the location of the shaped preform. The density of the shaped preform 200 can be varied by material selection for the fill component of the shaped preform 200 (discussed below).

[0123] The formed preform 200 is formed of a cured composite fiber material having a compressibility of less than 2% by volume, preferably less than 1% by volume, under molding conditions of a hydrostatic pressure of 50 bar and a process temperature of 60° C. to 150° C., preferably 60° C. to 140° C. With regard to curing, it is understood that the cured composite fiber material has undergone at least a partial curing process to harden or cure the curable matrix material (such as a resin) in the composite fiber material. The cured composite fiber material provides structural rigidity and / or robustness to the preform, thereby providing limited compressibility to enable appropriate volume and minimal volume change to be provided during layup and molding of the face portion of the composite wheel.

[0124] While not wishing to be bound by any one theory, the shaped preform 200 is designed to provide a core material that can be used in the layup and curing process of the composite wheel 100. The mechanical and material properties of the shaped preform are also selected to minimize structural loads and stresses caused by material incompatibilities and volume changes during the layup, curing and post-curing processes when forming the composite wheel.

[0125] The mechanical properties of the formed preform 200 are designed to obtain optimal mechanical and material properties. A formed preform 200 without sufficient tensile modulus in the thickness direction of the body will not effectively unload the flange to sidewall connection and therefore has little structural value. A formed preform 200 with excessive tensile modulus in the thickness direction of the body will result in excessive through thickness stress in the flange as the flange attempts to separate from the formed preform 200 and cause damage within the flange itself or at the connection between the flange and the formed preform 200. A properly designed formed preform 200 will unload the flange to sidewall connection without generating excessive through thickness stress in the flange.

[0126] Any number of different composite fiber materials may be used that include or may be bounded by a curable matrix material, such as a resin, to form a cured composite fiber material having a selected or desired density suitable to counteract the mass addition of the composite wheel 100. Density variation may be achieved by careful selection of the components of the shaped preform 200. In some embodiments, the shaped preform is formed of a resin (neat resin) or is formed substantially only of a resin. In an embodiment, the shaped preform is formed from at least one of: a customized fiber-implanted ply or preform; one or more single-fiber oriented ply layers (unidirectional); one or more multi-directional fiber ply layers (e.g., a stitched non-crimped fabric); or a fiber patch implanted (FPP) preform, such as CEVOTECH technology; a non-woven isotropic or anisotropic fiber layer, such as RECATEX recycled carbon fiber nonwoven fabric; an isotropic fiber arrangement; a filler; glass microspheres; hydrophobic fumed silica; an epoxy resin / hardener; a phenolic resin; milled carbon fiber; pulverized carbon fiber (e.g., chopped or chopped carbon fiber), or a combination thereof.

[0127] In a preferred form, the shaped preform component is formed from:

[0128] (i) A mixture of resin, milled carbon fiber or pulverized carbon fiber and hollow glass microspheres.

[0129] (ii) A mixture of resin and milled carbon fibers.

[0130] (iii) A mixture of resin and pulverized carbon fibers (preferably chopped carbon fibers).

[0131] It should be appreciated that the resin also includes an amount of hardener.

[0132] Each of (i) and (ii) may optionally include 1 wt % to 5 wt %, preferably 1 wt % to 2 wt % of hydrophobic fumed silica.

[0133] The milled carbon fibers have a length of less than 500 μm, preferably less than 100 μm. For example, milled carbon fibers having a length of 100 μm, such as Carbiso TM MF. However, it will be appreciated that any brand of milled carbon fiber is suitable. Other fiber types of similar length may be used.

[0134] In other embodiments, comminuted carbon fibers, such as chopped carbon fibers, may be used. The comminuted carbon fibers may have a length of less than 20 mm, preferably less than 15 mm, more preferably between 1 mm and 15 mm. For example, comminuted carbon fibers having a length of about 12 mm may be used. Other fiber types of similar lengths may be used.

[0135] The following table 1 provides a preferred material as options A to F (ratios are in parts by mass):

[0136] Table 1: Exemplary shaped preform compositions

[0137]

[0138] In more detail, Option C may include:

[0139] 3.75 parts of epoxy resin;

[0140] 1 part 100 μm long milled carbon fiber; and

[0141] 0.56 parts of hollow glass microspheres.

[0142] In more detail, Option D may include:

[0143] 2 parts epoxy resin and hardener; and

[0144] 1 piece of 12mm long chopped carbon fiber.

[0145] Each of the above options may optionally include 1 wt% to 5 wt%, preferably 1 wt% to 2 wt% of hydrophobic fumed silica. It should be appreciated that alternative ratios to those provided in options A to F may also provide a satisfactory composition and customized density for the shaped preform. Thus, the ratios shown in the table may be varied to modify the density of the shaped preform to provide the desired quality, thereby customizing the density and quality of the preform for a particular application.

[0146] The microspheres used in the above components include 3MS28HS glass bubbles available from 3M Advanced Materials Division. These glass bubbles include thin-walled hollow spheres made of soda-lime-borate silicate glass with an average diameter of 30 μm, a crush strength (90% survival by volume) of 3000 psi, and a true density of 0.28 g / cc. However, it should be appreciated that other similar microspheres may also be used. For example, alternative hollow microspheres such as 3M K1 bubbles with a target crush strength of 250 psi and a true density of 0.125 g / cc, or 3MIM30K (or the like) with a crush strength of 28,000 psi and a true density of 0.60 g / cc may be used. A selection of possible 3M microspheres that may be used is provided in Table 2:

[0147] Table 2: 3M hollow glass microspheres (glass bubbles) that can also be used in the present invention:

[0148]

[0149] In an exemplary embodiment, the shaped preform part is formed from a mixture of mixed resin: milled carbon fiber: hollow glass microspheres in a ratio (parts by mass) of 3.75:1:0.56.

[0150] In the illustrated embodiment, the fibers in the cured composite fiber material of the composite wheel 100 include carbon fibers. However, it should be appreciated that a wide variety of fibers may be used in the present invention, including but not limited to fibers selected from the group consisting of carbon fibers, glass fibers, aramid fibers, synthetic fibers (such as acrylic, polyester, PAN, PET, PE, PP, or PBO fibers, etc.), bio-fibers (such as hemp, jute, cellulose fibers, etc.), mineral fibers (such as rock wool, etc.), metal fibers (such as steel, aluminum, brass, copper, etc.), boron fibers, or any combination thereof.

[0151] It should be appreciated that the thermal expansion characteristics of the shaped preform 200 are designed to be similar to and preferably substantially match the thermal characteristics of the entire composite material of the face portion of the composite wheel in which the shaped preform 200 is configured to be included. Matching the thermal expansion characteristics avoids damage such as delamination of the part (the shaped preform and the surrounding laminate material during the post-curing process).

[0152] The composite material (usually a carbon fiber laminate) formed adjacent to the shaped preform during the forming process must adhere to the shaped preform. The material type of the shaped preform must be able to achieve this, for example, epoxy resin can be used for the shaped preform, but polypropylene should not be used in general. After the shaping of the shaped preform, and before the layup of the shaped preform, the surface of the shaped preform must be activated to enable it to be combined with the subsequent injection operation (this operation can be achieved by chemical etching, mechanical abrasion, etc.).

[0153] Other mechanical properties of the shaped preform 200 of interest include:

[0154] Density – preferably 0.3 g / cm 3 Up to 3g / cm 3 and more preferably between 0.3 g / cm 3 Up to 2g / cm 3 and more preferably from 0.4 g / cm 3 To 1.8g / cm 3 In some embodiments, the density of the shaped preform is from 0.5 g / cm 3 To 1.5g / cm 3 ;

[0155] Tensile strength - preferably between 20 MPa and 80 MPa, more preferably from 20 MPa to 60 MPa;

[0156] Stiffness - It is preferably from 1.5 GPa to 30 GPa, more preferably from 5 GPa to 30 GPa, more preferably from 8 GPa to 30 GPa, and even more preferably from 10 GPa to 25 GPa. In some embodiments, the stiffness is from 1.5 GPa to 10 GPa. In other embodiments, the stiffness is from 8 GPa to 25 GPa.

[0157] However, it should be appreciated that these characteristics may vary depending on the material, wheel construction, and desired properties of the particular composite wheel.

[0158] The shaped preform 200 shown is formed by a standard composite molding process. In this process, the preferred material components described in Table 1 are measured and mixed, and then injected into a closed, heated mold. The mold is at 120°C and once filled, the mold is kept at 120°C for 10 minutes to cure the resin. However, it should be appreciated that other process temperatures can be used depending on the desired process parameters. The formed shaped preform is then demolded and moved to the surface preparation step. The cooperative forming mold has a mold cavity formed to provide the desired shape and configuration of the shaped preform 200. Suitable matrix materials can be selected from (but not limited to) resins based on unsaturated polyesters, polyurethanes, polyvinyl esters, epoxy resins, thermoplastics, and combinations thereof.

[0159] The curing step can be controlled to provide desired mechanical properties, including stiffness, surface properties, and compressibility. Thus, the mechanical properties of the shaped preform 200 can be designed to suit a particular application. However, it must be appreciated that the shaped preform 200 is cured and otherwise processed to provide a selected compressibility that provides minimal volume change during subsequent fiber layup and molding process steps to form the face portion 104 of the composite wheel 200.

[0160] As described above, the cured shaped preform 200 is used as a layup aid or insert in the layup of the face portion 104 of the composite wheel 100. In this process, the shaped preform 200 is positioned in the spoke portion 108 of the fiber layup of the face portion mold; and the composite fiber elements of the face portion 104 are laid up around the shaped preform 200, thereby forming a preformed structure of the face portion of the composite fiber wheel.

[0161] Likewise, the fiber elements of the face portion layup may be provided in any suitable form, including prepregs, semipregs, woven or nonwoven fabrics, mats, preforms, preconsolidated preforms, individual or grouped fibers, tows, tow pregs, etc. During layup, a matrix material such as a resin need not be included in or between the layers comprising the fibers. However, the matrix material should form a continuous matrix after curing.

[0162] The composite wheel 100 ( Figure 1 and Figure 2) is intended to be formed as a one-piece body. This involves injecting and / or impregnating a matrix material (resin in the exemplary embodiment) into all parts including the rim portion 102 and the face portion 104 simultaneously, and then curing each part of the composite wheel 100. The resin used is preferably epoxy-based. However, it should be understood that any suitable resin may be used, such as unsaturated polyesters, polyurethanes, polyvinyl esters, epoxies, thermoplastics, similar compounds, or combinations thereof. A variety of resin delivery systems may be used, including but not limited to resin infusion and / or resin transfer molding and / or vacuum assisted resin transfer molding.

[0163] In the construction Figure 1 and Figure 2 In the case of the composite wheel shown, the wheel comprises three main mould faces. First is the face mould which is oriented generally radially with respect to the axis of rotation XX of the wheel. Second is the inner side 140 ( Figure 2 ). The inner barrel-shaped mold face comprises: a front side, which forms the rear mold wall of the face portion radially oriented with respect to the rotation axis XX of the wheel; and a side wall, which forms the rear mold wall of the rim portion and is radially aligned with the rotation axis XX of the wheel. The third is a rim mold substantially axially aligned with the rotation axis XX of the wheel.

[0164] In use, the rim portion 102 and the face portion 104 are laid up with reinforcements, and then the connection between the rim portion 102 and the face portion 104 is laid up with reinforcements. After the connection is formed, resin is injected and / or impregnated into the reinforcements of each of the rim portion 102 and the face portion 104 of the wheel 100 and then allowed to cure.

[0165] Those skilled in the art will appreciate that the invention described herein is subject to variations and modifications other than those specifically described. It should be understood that the invention includes all such variations and modifications that fall within the spirit and scope of the invention.

[0166] When the terms "comprises", "comprising", "including" or "comprising" are used in this specification (including the claims), they should be interpreted as specifying the presence of stated features, integers, steps or components, but not excluding the presence of one or more other features, integers, steps, components or combinations thereof.

Claims

1. A composite wheel, comprising: Spoke part; a shaped preform component for said spoke portion; and mass additions, the mass additions comprising unbalanced mass additions of the composite wheel, Wherein, the formed preform component comprises: an elongated body configured to be positioned within a spoke of a composite wheel, and wherein the shaped preform part is formed of a cured composite fiber material having a compressibility of less than 2% by volume under molding conditions of a hydrostatic pressure of 50 bar and a temperature of 60° C. to 150° C., And wherein the density of the cured composite fiber material is selected to form a counterbalancing mass of the mass addition of the composite wheel.

2. The composite wheel according to claim 1, wherein: The mass addition includes a valve.

3. The composite wheel according to claim 2, wherein: The valve is a tire pressure monitoring valve.

4. The composite wheel according to claim 1, wherein: The compressibility of the shaped preform part under molding conditions at a hydrostatic pressure of 50 bar is less than 1% by volume.

5. The composite wheel according to claim 1, wherein: The density of the formed preform part is 0.3g / cm 3 Up to 3g / cm 3 between.

6. The composite wheel according to claim 1, wherein: The shaped preform part has at least one of the following: A tensile strength between 20 MPa and 80 MPa; or Stiffness from 1.5GPa to 30GPa.

7. The composite wheel according to any one of claims 1 to 6, wherein: The surface of the shaped preform part has a rough surface with a roughness of at least Ra=0.2 μm.

8. The composite wheel according to claim 7, wherein: The rough surface includes a chemically etched surface or a mechanically abraded surface.

9. The composite wheel according to any one of claims 1 to 6, wherein: The shaped preform component is formed from the following materials: at least one layer of non-woven isotropic or anisotropic fibers; isotropic fiber arrangement; orthotropic fiber arrangement; filler; glass microspheres; ceramic microspheres; barium sulfate; hydrophobic fumed silica; epoxy resin; phenolic resin; milled carbon fiber; pulverized carbon fiber; or a combination thereof.

10. The composite wheel according to claim 9, wherein: The epoxy resin is a hardener.

11. The composite wheel according to claim 9, wherein: The glass microspheres include hollow microspheres.

12. The composite wheel according to any one of claims 1 to 6, wherein: The shaped preform part is formed from the following materials: (i) a mixture of resin, milled carbon fibers and hollow glass microspheres; (ii) a mixture of resin, crushed carbon fibers and hollow glass microspheres; (iii) a mixture of resin and hollow glass microspheres; (iv) a mixture of resin and milled carbon fibers; (v) a mixture of resin and pulverized carbon fibers; (vi) a mixture of resin, milled carbon fibers and solid ceramic microspheres; (vii) a mixture of resin, crushed carbon fibers and solid ceramic microspheres; (viii) a mixture of a resin and solid ceramic microspheres; or (ix) Substantially only resin.

13. The composite wheel according to claim 12, wherein: The resin includes a mixture of a resin and a resin hardener.

14. The composite wheel according to claim 9, wherein: The shaped preform further includes 1 wt % to 5 wt % of hydrophobic fumed silica.

15. The composite wheel according to claim 9, wherein: The milled carbon fibers have a length of less than 500 μm.

16. The composite wheel according to any one of claims 1 to 6, further comprising a curable matrix material surrounding constituent components of the shaped preform component.

17. The composite wheel according to claim 16, wherein: The matrix material includes a resin based on unsaturated polyester, polyurethane, polyvinyl ester, epoxy resin, thermoplastic or a combination thereof.

18. The composite wheel according to any one of claims 1 to 6, wherein: The shaped preform component has thermal properties designed to substantially match thermal properties of the overall composite material of a face portion of a composite wheel in which the shaped preform is configured to be included.

19. The composite wheel according to any one of claims 1 to 6, wherein: The shaped preform part comprises an incomplete or incompletely cured preform.

20. The composite wheel according to any one of claims 1 to 6, wherein: The elongated body is a rectangular parallelepiped body.

21. The composite wheel according to claim 20, wherein: The shaped preform part includes at least two arms extending laterally outwardly from one end of the elongated body.

22. The composite wheel of claim 20, wherein: The shaped preform component includes at least one L-shaped end portion extending axially outwardly from one end of the elongated body.

23. The composite wheel according to any one of claims 1 to 6, wherein: The shaped preform part comprises at least one of the following features: The fiber plies maintain the structure; Guide lines that visually indicate where the edge of the ply should be located; or Holding / manipulating structure for optimizing the handling of the shaped preform part.

24. The composite wheel according to any one of claims 1 to 6, wherein: The shaped preform is integrally formed with the composite wheel.

25. A method of forming a face portion of a composite fiber wheel, comprising: positioning a shaped preform component in a spoke portion of a fiber layup of a face portion of a composite wheel at a location suitable for balancing a mass addition about a central axis of the face portion of the composite wheel; as well as laying a composite fiber element around the shaped preform part to form a preformed structure of a spoke portion of a composite fiber wheel, Therein, the shaped preform part is an elongated body formed from a solidified composite fiber material having a compressibility of less than 2% by volume under forming conditions of a hydrostatic pressure of 50 bar and a temperature of 60° C. to 150° C.

26. The method according to claim 25, further comprising the steps of: providing a base material in contact with the preformed structure of the facial portion; and The facial portion is allowed to cure.

27. The method according to claim 25, wherein: The method further comprises the following steps: simultaneously providing a base material in contact with each of the rim portion and the face portion of the wheel; and The rim portion and the face portion of the wheel are cured simultaneously.

28. A method according to any one of claims 25 to 27, wherein: The fiber elements of the fiber layup of the face portion of the composite fiber wheel include carbon fibers.

29. The method according to any one of claims 25 to 27, wherein: The fiber element is provided as at least one of the following: a prepreg, a semipreg, a woven or non-woven fabric, a mat, a preform, a preconsolidated preform, individual or grouped fibers, a tow, a tow preg.

30. The method according to any one of claims 25 to 27, wherein: The fiber element is provided as at least one textile sheet.

31. A method according to any one of claims 25 to 27, comprising a composite fiber wheel according to any one of claims 1 to 24.

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