Wheel for a vehicle

Abstract

Aspects of the present invention relate to a wheel for a vehicle, a vehicle and a method of manufacturing a wheel for a vehicle. There is provided a wheel (100) for a vehicle (600) comprising a hub (1

Description

TECHNICAL FIELD The present disclosure relates to a wheel for a vehicle. Aspects of the invention relate to a wheel for a vehicle, a vehicle and a method of manufacturing a wheel for a vehicle BACKGROUND Wheels of vehicles typically comprise a central hub, an outer rim and spokes extending radially therebetween. The stiffness of the spokes relative to the hub (i.e. the “stiffness ratio” determines the location of a failure point in the event of an impact with the wheel (e.g. a kerb strike). When designing vehicle wheels, there are often many functional and aesthetic requirements to be considered and each selected design feature may impact the stiffness ratio such that a wheel may fail at an undesirable location. It is an aim of the present invention to address one or more of the disadvantages associated with the prior art. SUMMARY OF THE INVENTION Aspects and embodiments of the invention provide a wheel for a vehicle, a vehicle and a method of manufacturing a wheel fora vehicle as claimed in the appended claims. According to an aspect of the present invention there is provided a wheel fora vehicle comprising: a hub; a rim; and at least one spoke extending between the hub and the rim; wherein the hub has a generally cylindrical centre bore extending along a longitudinal axis of said hub, the centre bore comprising: a first section having a first internal radius and a second section having a second internal radius; wherein the second internal radius is larger than the first internal radius; and wherein the first section has a first radial thickness that is greater than 5 mm. According to another aspect of the present invention there is provided a wheel for a vehicle comprising: a hub; a rim; and at least one spoke extending between the hub and the rim; wherein the at least one spoke comprises at least one mounting point for mounting a trim component to the wheel; and wherein the hub has a generally cylindrical centre bore extending along a longitudinal axis of said hub, the centre bore comprising: a first section having a first internal radius and a second section having a second internal radius; wherein the second internal radius is larger than the first internal radius; and wherein the first section has a first radial thickness that is greater than 5 mm. A wheel having such features is advantageously found to provide a desired stiffness ratio in spite of the provision of the mounting points. In particular, a first radial thickness of greater than 5 mm provides the hub with sufficient mass to maintain a desired stiffness ratio. Additionally, such a configuration still permits a variety of standard tools to be received in the centre bore, where such tools may be required during the assembly of a vehicle comprising the wheel. In certain embodiments, the wheel comprises a plurality of spokes, each spoke comprising a shaft and a web part extending from the shaft such that the web parts extend between adjacent shafts, wherein the web parts comprise the at least one mounting point. Providing the mounting points on web parts that extend from the shafts is both convenient and effective. In certain embodiments, the first radial thickness may be greater than 5 mm and up to 13 mm. Such a range is advantageously found to provide a desired stiffness ration whilst accommodating a variety of standard tools in the centre bore that may be used during the assembly of a vehicle comprising the wheel. In certain embodiments, the mounting points may be formed of the same material as the at least one spoke. The advantages associated with a wheel having the above-described configuration may be particularly notable in embodiments in which the mounting points are formed of the same material as the plurality of spokes. In certain embodiments, one or more (or all) of the hub, the rim, the at least one spoke and the mounting points may comprise one of an aluminium alloy or a magnesium alloy. Such materials provide the wheel with particularly desirable mechanical properties. In certain embodiments, the centre bore may comprise an intermediate section located intermediate the first and second sections. In certain embodiments, the intermediate section has a frustoconical shape. In alternative embodiments, the intermediate section has a stepped tapered profile transitioning from the first internal radius to the second internal radius along a direction parallel to the longitudinal axis. Such formations may be advantageous in permitting certain tools to be receivable in the centre bore whilst still providing the wheel with the desired stiffness ration. In certain embodiments, the hub may comprise a radially inwardly projecting flange that defines a recess for receiving a badge or trim component. Such features may help accommodate components that improve the visual appearance of the wheel. In certain embodiments, the hub may comprise a plurality of bores for receiving wheel studs and / or lug nuts. In such embodiments, the hub may have additional functionality beyond facilitating the alignment of the wheel on an axle of the vehicle. According to another aspect of the present invention there is provided a vehicle comprising at least one wheel as described above. According to another aspect of the present invention there is provided a method of manufacturing a wheel for a vehicle comprising casting a wheel that comprises: a hub; a rim; and at least one spoke extending between the hub and the rim; wherein the hub has a generally cylindrical centre bore extending along a longitudinal axis of said hub, the centre bore comprising: a first section having a first internal radius and a second section having a second internal radius; wherein the second internal radius is larger than the first internal radius; and wherein the first section has a first radial thickness that is greater than 5 mm. According to another aspect of the present invention there is provided a method of manufacturing a wheel for a vehicle comprising casting a wheel that comprises: a hub; a rim; and at least one spoke extending between the hub and the rim; wherein the at least one spoke comprises at least one mounting point for mounting a trim component to the wheel; and wherein the hub has a generally cylindrical centre bore extending along a longitudinal axis of said hub, the centre bore comprising: a first section having a first internal radius and a second section having a second internal radius; wherein the second internal radius is larger than the first internal radius; and wherein the first section has a first radial thickness that is greater than 5 mm. In accordance with such methods, a wheel for a vehicle having the advantages noted above may be formed by casting and without any subsequent manufacturing steps (e.g. such as machining). In certain embodiments, the wheel may comprise any of the above-described features. In particular, in certain embodiments, the first radial thickness may be greater than 5 mm and up to 13 mm. Such a range is advantageously found to provide a desired stiffness ration whilst accommodating a variety of standard tools in the centre bore that may be used during the assembly of a vehicle comprising the wheel. Within the scope of this application it is expressly intended that the various aspects, embodiments, examples and alternatives set out in the preceding paragraphs, in the claims and / or in the following description and drawings, and in particular the individual features thereof, may be taken independently or in any combination. That is, all embodiments and / or features of any embodiment can be combined in anyway and / or combination, unless such features are incompatible. The applicant reserves the right to change any originally filed claim or file any new claim accordingly, including the right to amend any originally filed claim to depend from and / or incorporate any feature of any other claim although not originally claimed in that manner. BRIEF DESCRIPTION OF THE DRAWINGS One or more embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings, in which: Figure 1 shows part of a wheel of a vehicle in accordance with an embodiment of the present invention; Figure 2 shows cross-sectional view of a part of the wheel of Figure 1; Figure 3 shows an alternative cross-sectional view of a part of the wheel of Figure 1; Figure 4 shows the external profile of the hub of the wheel of Figure 1; Figure 5 shows a method of manufacturing awheel in accordance with an embodiment of the present invention; and Figure 6 shows a vehicle in accordance with an embodiment of the invention. DETAILED DESCRIPTION With reference to Figure 1, there is illustrated a wheel 100 for a vehicle in accordance with an embodiment of the present invention. The wheel 100 comprises one or more metallic materials (e.g. a metallic alloy). In certain embodiments, the wheel 100 comprises an aluminium alloy or a magnesium alloy. In manufacturing the wheel 100, the wheel 100 is initially formed (e.g. by casting) and subsequently undergoes further processes to form certain features and / or create desired surface finishes. The wheel 100 has a first surface 100a (the so-called “A-surface”) that is visible when the wheel 100 is mounted on a vehicle, and a second surface 100b on the opposite side (which is generally not visible when the wheel 100 is mounted on a vehicle). The wheel comprises a hub 102 centred on a central wheel axis 110 (which forms a longitudinal axis of the hub 102), a rim 104 extending circumferentially about the hub 102 and the wheel axis 110, and a plurality of spokes 106 extending radially between the hub 102 and the rim 104. Each spoke 106 comprises a shaft 112, and a web part 114 extending from the shaft 112. The web parts 114 extend between certain adjacent shafts 112. The web parts 114 comprise mounting points 108 for mounting a trim component (not shown) to the wheel 100. However, in other embodiments, the mounting points 108 may be provided on one or more other parts of each spoke 106. In certain embodiments, the mounting points 108 may be formed of the same material as the plurality of spokes 106. In certain embodiments, one or more (or all) of the hub 102, the rim 104, the plurality of spokes 106 and the mounting points 108 comprise one of an aluminium alloy ora magnesium alloy. The hub 102 has a generally cylindrical centre bore 116 that extends along the wheel axis 110, and a plurality of bores 118 for receiving wheel studs and / or lug nuts to facilitate attachment of the wheel 100 to a vehicle. In use, the centre bore receives a mounting hub or spigot of the vehicle to centre the wheel on an axle of the vehicle. The rim 104 is configured to receive and retain a tyre (not shown) and the spokes 106 maintain the rim 104 about the hub 102 and provide a force path therebetween. In use, the wheel 100 rotates on the vehicle about the wheel axis 110. The stiffness of the spokes 106 relative to the hub 102 (i.e. the stiffness ratio) determines the location of a failure point in the event of an impact with the wheel (e.g. a kerb strike). The provision of the mounting points 108 is found to increase the stiffness of the spokes 106 compared to otherwise identical spokes 106 that do not have such mounting points 108. As such, the provision of the mounting points 108 requires additional modifications to the hub 102 in order to maintain a desired stiffness ratio. In the absence of such additional modifications, the hub 102 of the wheel 100 may undesirably fail in the event of an impact with the wheel (e.g. a kerb strike) since forces may be disproportionately directed to the hub 102. In embodiments of the present invention, a desirable stiffness ratio is maintained by providing the hub 102 with sufficient mass to provide a desirable stiffness. A cross-sectional view of the wheel 100 is shown in Figure 2 which provides a detailed view of the hub 102. The centre bore 116 of the hub 102 comprises a first section 120 and a second section 122 that each extend along the wheel axis 110. The first section 120 has a first internal radius R1 (defined by the radial distance between an internal surface of the first section 120 and the wheel axis 110). The second section 122 has a second internal radius R2 (similarly defined by the radial distance between an internal surface of the second section 122 and the wheel axis 110). In certain embodiments of the present invention such as the embodiment shown in the figures, the second internal radius R2 is larger than the first internal radius R1. Moreover, the first section 120 has a first radial thickness T1 defined by the radial distance between the internal surface of the first section 120 and an external surface of the first section 120. The external surface of the first section 120 also defines part of internal surfaces of the plurality of bores 118. Similarly, the second section 122 has a second radial thickness T2 defined by the radial distance between the internal surface of the second section 122 and an external surface of the second section 122. The external surface of the second section 122 also defines part of the internal surfaces of the plurality of bores 118. The first radial thickness T1 is greater than 5mm. Accordingly, the total mass of the hub 102 is maintained to a desirable degree such that the stiffness ratio of the spokes 106 relative to the hub 102 is desirably maintained despite the presence of the mounting points and their effect on the stiffness of the spokes 106. In particular, the narrower first section 120 provides sufficient reinforcement to the hub 102 as a whole to provide a desirable stiffness ratio. In certain embodiments, the first radial thickness T1 is greater than 5 mm and up to 13 mm. The first section 120 and the second section 122 define at least part of the internal profile of the centre bore 116. In certain embodiments, the transition between the internal surface ofthe first section 120 and the internal surface ofthe second section 122 may be stepped, tapered or comprise a series of tapered sections having different taper angles (effectively forming a stepped taper). In the non-limiting embodiment shown in the Figures an intermediate section 124 is disposed between the first section 120 and the second section 122 along a direction parallel to the wheel axis 110. In the depicted embodiment, the intermediate section 124 comprises a stepped tapered profile transitioning from the first internal radius R1 to the second internal radius R2 along a direction parallel to the wheel axis 110. The stepped tapered profile defines a generally frustoconical shape. In certain embodiments, the intermediate section 124 may define a smooth frustoconical shape (i.e. that does not include a series of tapered sections having different taper angles). In the non-limiting embodiment shown in the Figures, each ofthe first section 120 and the second section 122 has an internal surface that at least in part extends parallel to the wheel axis 110 (i.e. each has at least one straight, non-tapered internal surface). In certain embodiments, it is this part ofthe internal surface relative to the external surface that defines the thicknesses T1 and T2 ofthe first section 120 and the second section 122 respectively. In the non-limiting embodiment shown in the Figures, the second section 122 is closer to the second surface 100b than the first section 120 along a direction parallel to the wheel axis 110. Conversely, the first section 120 is closer to the first surface 110a than the second section 122 along a direction parallel to the wheel axis 110. In the non-limiting embodiment shown in the Figures, the first section 120 is axially longer (i.e. in a direction parallel to the wheel axis 110) than the second section 122. In other embodiments, the axial length ofthe first section 120 may be equal to or less than the axial length ofthe second section 122. In the non-limiting embodiment shown in the Figures, each ofthe plurality of bores 118 has a variable internal diameter along its axial length. Consequently, the internal surface of each ofthe plurality of bores 118 has a variable minimum distance from the wheel axis 110 in a direction parallel to the wheel axis 110. Since the internal surface of each ofthe plurality of bores 118 defines the external surfaces ofthe first section 120 and second section 122, the form ofthe bores 118, together with the first internal radius R1 and second internal radius R2, define the first radial thickness T1 and the second radial thickness T2. In the non-limiting embodiment shown in the Figures, the hub 102 comprises a radially inwardly projecting flange 126 which axially delimits one end ofthe centre bore 116. The flange 126 has a third internal radius R3 which is less than the first internal radius R1. Figure 3 shows an alternative cross-sectional view ofthe wheel 100 in which it can be seen that the flange 126 is axially offset (i.e. along a direction parallel to the wheel axis 110) from the first surface 100a such that the flange 126 defines a recess that may receive badge or trim component of the wheel 100. Neither the flange 126 nor the recess it defines form part of the centre bore 116 (which terminates at the flange 126). Figure 4 shows an external profile view of the hub 102 which shows the external surfaces of the first section 120 and the second section 122. In use, the centre bore 116 is required to fit over the axle hub (not shown) of a vehicle to align the wheel correctly on the vehicle. The centre bore 116 is additionally required to accommodate a variety of tools, including but not limited to a mounting machine, matching machine, bead-seat optimiser, uniformity testing machine, measuring balancer, and DOT reader, the sizes and / or shapes of which are determined by industry standards. As such, the form of the hub 102 and the centre bore 116 are constrained by the requirement to meet such industry-specific prerequisites. In order to conform to such requirements and still provide the desired technical effect, in certain embodiments the first internal radius R1 may be between 28.25 mm and 36.295 mm, and / or the second internal radius R2 may be between 36.29 mm and 36.325 mm, and / or the first radial thickness T1 may be greaterthan 5 mm and up to 13 mm, and / or the second radial thickness T2 may be between 14.7 mm and 14.735 mm. Figure 5 shows a method 500 of manufacturing a vehicle wheel 100 comprising, at block 502, casting the wheel 100 described above. That is, the casting process 502 (without the need for additional machining processes) produces the wheel 100 comprising the hub 102, the rim 104, the plurality of spokes 106 comprising mounting points 108, wherein the hub 102 has a generally cylindrical centre bore 116 extending along the wheel axis 110, wherein the centre bore 116 comprises a first section 120 having a first internal radius R1 and a second section 122 having a second internal radius R2 that is greaterthan the first internal radius R1. That is, no further processing (e.g. machining) steps may be required beyond casting in order to produce the vehicle wheel 100 having the hub 102, the rim 104, and the at least one spoke 106 extending between the hub 102 and the rim 104, wherein the at least one spoke 106 comprises the at least one mounting point 108 for mounting a trim component to the wheel 100, and wherein the hub 102 has the generally cylindrical centre bore 116 extending along the longitudinal axis 110 of the hub 102, the centre bore 116 comprising the first section 120 having a first internal radius R1 and the second section 122 having a second internal radius R2, wherein the second internal radius R2 is larger than the first internal radius R1; and wherein the first section 120 has a first radial thickness T1 that is greaterthan 5 mm. In certain embodiments, the first radial thickness is greater than 5 mm and up to 13 mm. Figure 6 shows a vehicle 600 including a wheel 100 according to an example embodiment of the present invention. It will be appreciated that various changes and modifications can be made to the present invention without departing from the scope of the present application.

Claims

1. A wheel for a vehicle comprising:a hub;a rim; andat least one spoke extending between the hub and the rim;wherein the at least one spoke comprises at least one mounting point for mounting a trim component to the wheel; andwherein the hub has a generally cylindrical centre bore extending along a longitudinal axis of said hub, the centre bore comprising:a first section having a first internal radius and a second section having a second internal radius;wherein the second internal radius is larger than the first internal radius; and wherein the first section has a first radial thickness that is greater than 5 mm.

2. The wheel of claim 1, wherein the first radial thickness is greater than 5 mm and up to 13 mm.

3. The wheel of claim 1 or 2, comprising a plurality of spokes, each spoke comprising a shaft and a webpart extending from the shaft such that the web parts extend between adjacent shafts, wherein the web parts comprise the at least one mounting point.

4. The wheel of any of claims 1 to 3, wherein the mounting points are formed of the same material as the at least one spoke.

5. The wheel of any preceding claim, wherein one or more of the hub, the rim, the at least one spoke and the mounting points comprise one of an aluminium alloy ora magnesium alloy.

6. The wheel of any preceding claim, wherein the centre bore comprises an intermediate section located intermediate the first and second sections.

7. The wheel of claim 6, wherein the intermediate section has a frustoconical shape.

8. The wheel of claim 6, wherein the intermediate section has a stepped tapered profile transitioningfrom the first internal radius to the second internal radius along a direction parallel to the longitudinal axis.

9. The wheel of any preceding claim, wherein the hub comprises a radially inwardly projecting flange that defines a recess for receiving a badge or trim component.10 The wheel of any preceding claim, wherein the hub comprises a plurality of bores for receiving wheel studs and / or lug nuts.

11. A vehicle comprising at least one wheel according to any preceding claim.

12. A method of manufacturing a wheel for a vehicle comprising casting a wheel that comprises:a hub;5 a rim; andat least one spoke extending between the hub and the rim;wherein the at least one spoke comprises at least one mounting point for mounting a trim component to the wheel; andwherein the hub has a generally cylindrical centre bore extending along a longitudinal axis of10 said hub, the centre bore comprising:a first section having a first internal radius and a second section having a second internal radius;wherein the second internal radius is larger than the first internal radius; and wherein the first section has a first radial thickness that is greater than 5 mm.1513. The method of claim 12, wherein the first radial thickness is greater than 5 mm and upto 13 mm.10

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