Improved Outer Surface of Carbon Fiber Wheel

Abstract

A carbon fiber wheel for a vehicle is provided, the wheel body comprising a rim portion and a face portion, the rim portion comprising an annular structure configured to receive and seat a tire, the face portion comprising a hub configured to secure the wheel to the vehicle and a connecting structure extending between the hub and the rim and interconnecting the hub and the rim, the wheel body having an inner side configured to face a wheel mount of the vehicle and an outer side configured to face outward when connected to the wheel mount of the vehicle, the wheel body comprising: a wheel body formed from a first carbon fiber composite composition comprising a carbon fiber layup infused with a first resin; and a fascia layer attached to at least a portion of the outer face portion of the wheel body, the fascia layer being formed from a second fiber composite composition comprising a selected fiber layup infused with a second resin.

Description

Technical Field

[0001] Cross - reference to Priority This application claims the priority of Australian Provisional Patent Application No. 2020901840, filed with the Australian Patent Office on June 4, 2020, the content of which is to be understood as incorporated herein by reference.

Background Art

[0002] Technical Field The present invention generally relates to carbon fiber wheels having an aesthetically improved outer surface or outer face. The present invention is particularly applicable to composite carbon fiber wheels for vehicles, and it will be convenient to disclose the present invention below in relation to its exemplary uses. However, it should be understood that the present invention is not limited to such uses and can be used as an aid in the manufacture of a wide variety of composite wheels.

[0003] Background of the Invention The following discussion regarding the background of the present invention is intended to facilitate the understanding of the present invention. However, it should be understood that this discussion is not an admission or approval that any of the materials mentioned are publicly available, known, or part of common general knowledge as of the priority date of this application.

[0004] The applicant has manufactured, for example, the integral composite wheels described in International Publication No. WO 2010 / 025495 pamphlet and International Publication No. WO 2019 / 033169 pamphlet. The production of integral composite wheels generally requires the use of separate rim part - molds and related reinforcements, as well as face part - molds and related reinforcements. At this time, the separate rim and face - type parts are interconnected in the final assembly and molding process, whereby the entire composite wheel can be integrally formed. Then, a final molding process is performed to inject and / or infuse a matrix material such as resin into the reinforcements throughout the wheel shape to manufacture the molded integral wheel.

[0005] Various resins can be injected into the reinforcing material of the entire wheel shape to manufacture a molded, one-piece wheel. In conventional carbon fiber wheels, structural resins, typically epoxy resins, are commonly used, and when cured, they provide the conventional almost translucent color. When this translucent resin is combined with black carbon fiber, the material exhibits a black appearance. This black cured color is considered aesthetically desirable and the expected appearance and color for carbon fiber products.

[0006] The applicant has found that carbon fiber wheels used in certain applications, such as high-performance automobiles, may require greater heat resistance and performance compared to standard resin-based wheels due to high temperature loads from nearby braking systems.

[0007] Carbon fiber components, including vehicle wheels, are pre-modified by applying a heat-shielding coating to the parts of the component that are exposed to high temperatures (see, for example, International Publication No. 2016168899). This allows the component to be constructed from a structural resin with lower thermal performance but that is aesthetically acceptable. However, the application of the heat-shielding coating inevitably covers the parts of the wheel that have a colored coating, which can add considerable cost. This can compromise the desired aesthetics and economics of the wheel.

[0008] Another solution is to use alternative types of materials with better thermal properties, such as high-temperature-performance structural resins or other thermal-performance additives, during the molding process. However, the resulting product may have an aesthetically unacceptable appearance. For example, some high-temperature-performance structural resins cure to a non-black, sometimes dark brown color, which does not provide the desirable, acceptable black carbon fiber appearance required for expensive, marketable products.

[0009] Furthermore, the applicant has found that current resin transfer molding processes generally introduce at least some surface defects into the outer surface of molded composite wheels. Aesthetic defects resulting from current wheel manufacturing processes incur quality costs that must be corrected. In some cases, not all of these aesthetic defects can be corrected after molding and before the clear coat or other painting processes. Therefore, certain surface defects can lead to product rejection, resulting in undesirable high waste costs. [Overview of the project] [Problems that the invention aims to solve]

[0010] Therefore, it is desirable to provide a novel or improved carbon fiber wheel configuration that can solve or at least improve one or more of the above problems. [Means for solving the problem]

[0011] Summary of the Invention The present invention provides a novel carbon fiber wheel configuration comprising a carbon fiber wheel body (structural wheel) including a carbon fiber fascia layer designed to cover at least a portion of the outer surface of the carbon fiber wheel body.

[0012] In a first embodiment, the present invention relates to a carbon fiber wheel for a vehicle, A wheel body comprising a rim portion and a face portion, wherein the rim portion comprises an annular structure configured to receive and seat a tire, and the face portion comprises a hub configured to fix the wheel to a vehicle and a connecting structure extending between the hub and the rim and interconnecting the hub and the rim, and the wheel body has an inner side configured to face the wheel mount of the vehicle and an outer side configured to face outward when connected to the wheel mount of the vehicle, and the wheel body is formed from a first carbon fiber composite composition comprising a carbon fiber layup into which a first resin is injected, The present invention provides a carbon fiber wheel comprising a fascia layer attached to at least a portion of the outer face of the wheel body, the fascia layer being formed from a second fiber composite composition having a selective fiber layup into which a second resin is injected.

[0013] The use of a fascia layer advantageously provides an improved surface finish compared to the surface of a bulk-molded carbon fiber wheel. The fascia layer consists of a much smaller and thinner layer (compared to a bulk wheel), allowing for easier control of its surface quality and finish. Therefore, the use of a fascia layer makes it possible to completely cover any aesthetic defects on the outside of the wheel body molding. The fascia layer is preferably designed to meet all aesthetic, structural, environmental, and performance requirements for this outer layer of the carbon fiber wheel.

[0014] When carbon fiber wheels are molded as a single unit, any defects on the outer or outer surface need to be corrected, adding to the correction costs. Certain defects can lead to product rejection, resulting in higher disposal costs. In comparison, the cost of adding a fascia layer to a pre-formed wheel body is significantly lower than the molding and manufacturing of a complete carbon fiber wheel, as well as the correction of any surface defects on the outer surface of a complete carbon fiber wheel. Generally, any surface finish defects in structural wheel molded products do not require correction because the adhesive and / or the fascia material itself fills the defects during the step of covering the outside of the wheel body and attaching the fascia layer. Thus, the fascia layer overlaps the outer surface of the wheel body, completing a carbon fiber wheel with an aesthetically pleasing external finish. Therefore, the use of a fascia layer can be cost-effective in quality inspection and part rejection related to surface finish defects.

[0015] The first resin of the wheel body and the second resin of the fascia layer may include any suitable resin. The first and second resins are preferably based on unsaturated polyester, polyurethane, polyvinyl ester, epoxy, thermosetting resin, thermoplastic resin, or a combination thereof. In some embodiments, the first and second resins may have the same or similar composition, where the fascia resin may be the same resin used in the structural wheel molded product. In other embodiments, the first resin has a different composition from the second resin.

[0016] The first resin is preferably selected as a structural resin. This resin can be selected as a resin containing one or more of the following properties: high durability, cost-effectiveness, high elongation at break, high thermal performance, or short curing cycle time. The first resin may contain desired mechanical properties for a particular application.

[0017] In some embodiments, at least the second resin has an aesthetically acceptable cured color. It should be understood that an aesthetically acceptable cured color means a color that is considered to provide the carbon fiber wheel with an aesthetically desirable, expected appearance and color. This generally requires that the carbon fiber wheel has a cured resin that allows the fibers to be visible, so that the color of the fibers—for example, black or near-black in the case of carbon fiber—is visible through the resin. It should be understood that the color “black” can have shades of black ranging from jet black to off-black. The term “black” as used herein is intended to include the various shades of black associated with carbon fiber composites. In some embodiments, the aesthetically acceptable cured color of the second resin is substantially clear or transparent. The cured second resin may also, in some forms, be at least one of translucent, glassy, ​​or transparent. Thus, in the case of carbon fiber composites, combinations of resins such as clear, transparent, or translucent (as described above) with black carbon fiber result in the material exhibiting an aesthetically desirable black appearance.

[0018] While the fiber color of many carbon fiber components (fibers, carbon fiber layups, recovered fiber portions, etc.) is conventionally black, it should be understood that in some embodiments, the fiber portions of the fascia layer can have any desired color depending on the fibers or mixtures of fibers selected to constitute the selected fiber layup of the fascia layer. Similarly, the resin color of the fascia layer can be selected to have any particular desired color. Therefore, embodiments of the present invention may have a fascia layer comprising a resin, selected fibers or mixtures of fibers, and / or other fiber layups having any particular desired color.

[0019] The selective fiber layup of the second fiber composition of the fascia layer may include one or more fibers (e.g., a single fiber or a mixture of two or more fibers) which are desirable to provide a specific color and pattern to the layup visible through the cured resin. It should be understood that the selective fiber layup can have any desired pattern, design or aesthetics formed from the fiber layup and any additional elements added to the layer. To form its design, the selective fiber layup can be formed from fibers selected from the group consisting of synthetic fibers such as carbon fibers, glass fibers, aluminum-processed glass fibers, aramid fibers, acrylic, polyester, PAN, PET, PE, PP, or PBO fibers; biofibers such as hemp, jute, or cellulose fibers; mineral fibers such as rock wool; metallic fibers such as steel, aluminum, brass, or copper; boron fibers; or any combination thereof. In embodiments, the selective fiber layup is preferably formed from one or more fibers selected from carbon fibers, aramid fibers or para-aramid fibers (e.g., Kevlar), glass fibers, polyester fibers, aluminum-processed glass fibers, etc. These fibers can be colored so that the selective fiber layup includes one or more fibers selected from colored glass fibers, colored polyester fibers, colored carbon fibers, etc. In some embodiments, the selective fiber layup includes carbon fibers having a certain amount of additional different fibers to provide a decorative element. However, in many embodiments, the selective fiber layup includes carbon fibers or at least substantially carbon fibers. In embodiments, the fascia layer is formed from a second fiber composite composition including a carbon fiber layup into which a second resin has been injected. In these embodiments, the fascia layer is typically laid up to look like a decorative outer layer of a carbon fiber component having a distinctive and aesthetically desirable black appearance and a regular carbon fiber layup patterning.

[0020] In embodiments, the first resin includes a thermal performance structural resin, preferably a high thermal performance structural resin. The thermal performance structural resin is preferably selected from at least one of resins including epoxy, bismaleimide, polyimide, benzoxazine, phenols, cyanate esters, polyurethane, polyester, or other thermosetting materials. The second resin may include any structural resin having an aesthetically acceptable cured color. The second resin is preferably selected from at least one of epoxy, polyurethane, polyester, or vinyl ester resins. In certain embodiments, the second resin includes a polyurethane resin, preferably a transparent polyurethane resin. In some embodiments, the second resin includes a UV-resistant resin.

[0021] When a high-temperature-performance structural resin is used, the present invention can provide an aesthetically acceptable carbon fiber wheel with high thermal performance. The high thermal performance is provided by the base carbon fiber wheel body formed from the high-temperature-performance resin, while the aesthetically acceptable carbon fiber appearance is provided by the outer fascia covering the outer surface (outward-facing front) of the face and rim portions of the carbon fiber wheel.

[0022] When the second resin includes a polyurethane resin, in some embodiments, the molded surface can be manufactured with a desired surface finish influenced by the machined surface design, such as high gloss, semi-gloss, matte, or textured, by using a desired textured or polished surface in the molding process. Polyurethane resins also offer the ability to achieve various opaque finishes, such as colored finishes, by adding pigments / colors to the fascia resin. The use of polyurethane resins can also enable the application of self-healing functionality to the face and other parts of the wheel body via a polyurethane transparent coating. Polyurethane resins do not require a protective coating, such as one applied by spray painting. Epoxy resins require a protective coating to protect the epoxy. Therefore, no additional protective coating or other surface finish, such as spray painting, is required. Polyurethane resins are also inherently more transparent than epoxy resins and therefore offer superior aesthetic advantages over other types of resins that can be used for the fascia layer.

[0023] The fascia layer can take on various forms. In the first embodiment, the fascia layer includes a molded fiber composite layer bonded to the wheel body, preferably bonded to the wheel body using an adhesive. In this embodiment, the fascia layer is preferably manufactured as a separate molded fiber composite layer component, typically as a resin transfer molding (RTM) component, and then attached to the outer face portion and optionally to at least a portion of the rim portion of the wheel body. The use of a molded fiber composite layer component advantageously provides an improved surface finish compared to the surface of a bulk-molded carbon fiber wheel. The molded fiber composite layer includes a much smaller and thinner molded portion (compared to a bulk wheel), and its surface quality and finish can be more easily controlled. Thus, the use of a molded fiber composite layer makes it possible to completely cover any aesthetic defects on the outside of the wheel body molded product. The fascia layer is preferably designed to meet all aesthetic, structural, and environmental performance requirements of the carbon fiber wheel.

[0024] The fascia layer (in the molded fiber composite layer embodiment) can be attached to the wheel body either permanently or in a replaceable / removable manner. In some embodiments, the fascia layer is fixedly attached to the wheel body. This can be achieved by various means including adhesives, molding, melting, mechanical or other integral attachment methods or means. In a preferred form, an adhesive is used to bond the molded fiber composite layer to the wheel body. Here, the carbon fiber wheel further includes an adhesive between the wheel body and the fascia layer, and the adhesive attaches the fascia layer to the wheel body. At least one of various adhesives such as epoxy, polyurethane, methacrylate or similar adhesives can be used.

[0025] The adhesive is preferably selected so that it can flow between the outer side of the wheel body and the inner surface of the fascia layer to fill any gaps, recesses, or cavities therebetween. Filling the space between the wheel body and the fascia layer using an adhesive can be more cost-effective than using a fibrous structural material. Thus, the adhesive preferably further includes a filling material disposed in any cavities, gaps, or recesses between the outer side of the wheel body and the inner surface of the fascia layer. The adhesive is preferably present in an amount that completely fills the space between the wheel body and the fascia layer. However, it should be understood that in some forms, an alternative, lower-cost filling material can replace part of the adhesive used to fill the cavities, gaps or recesses therebetween.

[0026] To assist in attachment, the outer side of the wheel body can include at least one recess or contour configured to cooperate and engage with the fascia layer. The recess or contour is preferably designed to receive the adhesive and allow the adhesive to flow between the outer side of the wheel body and the inner surface of the fascia layer.

[0027] The fascia layer of this first embodiment comprises a thin molded faceplate designed to cover the outside of the wheel body. The fascia layer is not intended to provide significant structural or mechanical properties to the wheel as a whole. However, it should be noted that the fascia layer may be subjected to strong stresses during use and therefore may provide some degree of mechanical integrity to the system. The wheel body is intended to provide the structural properties of a carbon fiber wheel. Therefore, the fascia layer is preferably composed of a wall / layer thickness of 0.1 to 10 mm, more preferably 0.2 to 10 mm. In some embodiments, the wall thickness of the fascia layer is 0.1 to 15 mm, more preferably 0.5 to 10 mm. In other embodiments, the wall thickness of the fascia layer is 1 to 8 mm, more preferably 2 to 6 mm. In yet another embodiment, the wall thickness of the fascia layer is 0.1 to 2 mm, more preferably 0.2 to 1 mm. In an exemplary embodiment, the wall thickness of the fascia layer is 1 to 2.5 mm. In the embodiment, the wall thickness of the fascia layer is at least 1 / 20 of the thickness / depth of the wheel body, more preferably at least 1 / 30 of the thickness / depth of the wheel body. In the embodiment, the wall thickness of the fascia layer is 1 / 20 to 1 / 500 of the thickness / depth of the wheel body, for example, 1 / 250 of the thickness / depth of the wheel body in a certain portion.

[0028] The adhesive used to bond the molded fascia to the molded wheel range preferably has a thickness of 50 to 400 micrometers, 100 to 300 micrometers in some embodiments, and more preferably about 200 micrometers.

[0029] The fascia layer is preferably composed of a molded and contoured outer surface. In embodiments, the fascia layer (and its outer surface) is composed of a more complex geometric shape than the outer surface of the wheel body, for example, design features to improve aesthetics. Thus, the present invention can enable the design of the wheel body with a simpler outer shape. The fascia layer can then be molded to the shape and contour of the desired or designed wheel configuration. Any defects on the outer surface of the wheel body are covered by the fascia layer, and aesthetically unacceptable surfaces are concealed by the designed fascia layer.

[0030] The fascia layer is preferably configured in a manner that is clearly not a secondary joint portion and is preferably attached / joined to the wheel body. This can be achieved by configuring the fascia layer to extend substantially over the entire outside of the wheel body, preferably configured to cover and conceal the entire surface of the face portion and the outer rim portion of the wheel body.

[0031] In a second embodiment, the fascia layer includes a fiber composite layer molded onto the wheel body. The molding process may include any suitable process steps. In an exemplary embodiment, the fascia layer includes an overmolded fiber composite layer, such as an overmolded carbon fiber composite layer. This overmolding process preferably includes a resin transfer molding (RTM) layer.

[0032] Similar to the first embodiment, this form of the fascia layer comprises a thin molded layer designed to cover at least a portion of the outside of the wheel body. The fascia layer is not intended to provide significant structural or mechanical properties to the wheel as a whole. The wheel body is intended to provide the structural properties of the carbon fiber wheel. Therefore, the fascia layer is preferably composed of a wall / layer thickness of 100 to 800 micrometers, preferably 150 to 800 micrometers, and more preferably 200 to 600 micrometers. In some embodiments, the wall thickness of the fascia layer is 200 to 450 micrometers. In some embodiments, the wall thickness of the fascia layer is 200 to 750 micrometers. In certain embodiments, the wall thickness of the fascia layer is 200 micrometers to 2 mm. Thicker fascia layers may result from the use of thicker layup materials, such as fiber mat material. In embodiments, the wall thickness of the fascia layer is at least 1 / 20 of the thickness / depth of the wheel body, more preferably at least 1 / 30 of the thickness / depth of the wheel body. In this embodiment, the wall thickness of the fascia layer is 1 / 20 to 1 / 500 of the thickness / depth of the wheel body, for example, 1 / 250 of the thickness / depth of the wheel body in a certain portion.

[0033] The fascia layer is preferably composed of molded and contoured outer surfaces. In embodiments, the fascia layer (and its outer surfaces) is composed of geometric shapes more complex than the outer surface of the wheel body, such as design features to improve aesthetics. Thus, the present invention can enable the design of the wheel body with a simpler outer shape. The fascia layer can then be molded to the shape and contour of the desired or designed wheel configuration. Any defects on the outer surface of the wheel body are covered by the fascia layer, and aesthetically unacceptable surfaces are concealed by the designed fascia layer. In embodiments, at least one solid insert can be bonded to the outer surface of the wheel body to provide contours or features beneath the fascia layer. The solid insert may contain any suitable compatible material, such as a filler composition, for example, a glass microsphere-filled epoxy resin or a thixotropic-filled epoxy resin.

[0034] The fascia layer is preferably attached to at least one of the outer face portion of the wheel body or at least a portion of the outer rim portion of the wheel body. In a preferred embodiment, the fascia layer is attached to / on at least the outer face portion of the wheel body. In this regard, the fascia layer is more preferably configured to cover at least the entire surface of the outer face portion of the wheel body. However, in embodiments, the fascia layer may also be attached to at least a portion of the outer rim portion of the wheel body. Thus, in some embodiments, the fascia layer is configured to cover the entire surface of the outer face portion of the wheel body and a portion of the rim portion. In other embodiments, the fascia layer is configured to cover only a portion of the outer rim portion of the wheel body.

[0035] The fascia layer in various embodiments is generally configured to have at least some degree of general geometric cooperation with the wheel body, more specifically the outside of the wheel body. In embodiments, the inside of the fascia layer is molded in a cooperating geometric shape, preferably substantially complementary to the geometric shape of the outside of the wheel body. The overall contours of the fascia layer and the wheel body (more specifically, the inside of the fascia layer and the outside of the wheel body) are preferably designed to cooperate in order to help the two parts adhere together. Thus, the fascia layer is preferably configured to cooperate with the face and rim portions of the outside of the wheel body, and preferably with the cooperating contours of the connecting, hub, and rim portions of the wheel body.

[0036] In some embodiments, the hub of the wheel body is substantially circular in shape with respect to a central axis and comprises at least one recess. Therefore, the fascia layer is preferably composed of cooperating shapes and recesses. The hub may comprise three or more spaced recesses around the central axis, and possibly at least four spaced recesses around the central axis. The fascia layer is composed of similar cooperating configurations. Similarly, if the hub includes a central opening, the fascia layer is composed of cooperating central openings. In some embodiments, this central opening includes the step of forming a rim or flange at one end of the opening. The fascia layer is composed of cooperating shapes.

[0037] The fascia layer also preferably includes at least one opening into which a wheel mounting configuration, including fastening bolts (a center bolt or a plurality of wheel mounting bolts), is inserted. In a preferred embodiment, these openings are configured to cooperate to receive corresponding portions of the wheel mounting configuration taught in the applicant's International Publication No. 2013 / 000009 and International Publication No. 2015 / 027271, whose contents should be understood to be incorporated herein by this reference.

[0038] In some embodiments, the wheel body connection structure may include a series of annularly spaced spokes. In such embodiments, the fascia layer may include a series of cooperating annularly spaced spokes. Similarly, the spokes may have elongated bodies that taper or slope inward from the hub towards the rim portion. In these embodiments, the fascia layer is composed of cooperating shapes.

[0039] The wheel / wheel body may include further portions covered or coated by another adhesive layer. In some embodiments, the rim portion of the molded wheel body includes an inner circumferential surface, which includes a resin cover layer comprising a second resin and has a configuration that cooperates with the inner circumferential surface of the wheel body. It should be understood that the inner circumferential surface of the rim portion preferably includes an inner barrel surface that is positioned around the wheel mount of the vehicle and configured to face the wheel mount of the vehicle. The inner barrel surface comprises an inner annular surface of the rim that forms the inner annular wall of the rim portion of the wheel body. The resin cover layer preferably has a thickness of 100 to 800 micrometers, preferably 200 to 500 micrometers, and more preferably less than 500 micrometers. In some embodiments, the resin cover layer has a thickness of 5 to 500 micrometers, more preferably 10 to 400 micrometers. In some embodiments, the resin cover layer has a thickness of 10 to 500 micrometers, more preferably 10 to 100 micrometers. If the second resin includes polyurethane, this embodiment can provide a finished transparent coating gloss surface on the main visible surfaces of the composite wheel (i.e., the fascia surface and inner barrel surface covered by the resin cover layer) when the wheel is mounted on the wheel mount of the vehicle.

[0040] The fascia layer and the molded body can be formed by various resin-based molding systems known in the art. One preferred system is resin transfer molding (RTM). In embodiments, the fascia layer and / or the wheel body include resin transfer molded (RTM) parts.

[0041] The fiber reinforcement for the wheel body and fascia layer can be formed from at least one of the following: fiber layers, fiber plies, prepregs, semipregs, woven or nonwoven fabrics, mats, preforms, pre-compacted preforms, individual fibers, tows, or tow pregs, or groups thereof.

[0042] It should be understood that prepregs refer to substantially or completely impregnated assemblies of fibers, fiber tows, woven fabrics, or nonwoven fabrics. Similarly, semipregs should be understood to refer to partially impregnated assemblies of fibers or fiber tows. Partial impregnation improves the removal of gases through or along dry fibers during compaction and / or curing. An example of a semipreg is a partially impregnated layer of fibers.

[0043] It should be understood that dry carbon fiber reinforcements (including tow-based structures and woven and nonwoven fabrics) are substantially dry, i.e., aggregates of individual fibers or fiber tows that are not impregnated with a matrix material such as resin. It should also be 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 preg is a fiber tow that is at least partially impregnated.

[0044] The carbon fibers may be supplied in any desired orientation within the transition zone, such as unidirectional, biaxial, random, or a combination thereof. However, the fibers are preferably oriented to reduce stress between composite members and to reinforce areas of the final structure that are subjected to higher stress during use. The orientation of the fibers may or may not be the same in all layers containing fibers within the transition zone. For example, if stress analysis suggests multiaxial fiber orientation, one or more layers of fibers may be oriented differently from the others. However, in other embodiments, the fibers may be oriented substantially the same in all layers of fibers.

[0045] In some embodiments, the fascia layer may include at least one fiber layer positioned on the outer face portion of the wheel body and optionally on a portion of the rim. In some embodiments, the fascia layer may include a carbon fiber ply of 150 to 300 gsm, preferably a carbon fiber ply of 200 to 250 gsm. Various forms of plies, such as plain weave plies or twill weave plies, may be used.

[0046] A second aspect of the present invention is a method for forming a carbon fiber wheel, The present invention relates to forming a molded wheel body from a first carbon fiber composite composition comprising a first carbon fiber layup into which a first resin is injected, wherein the molded wheel body comprises a rim portion and a face portion, the rim portion comprising an annular structure configured to receive and seat a tire, the face portion comprising a hub configured to secure the wheel to a vehicle and a connecting structure extending between the hub and the rim and interconnecting the hub and the rim, and the wheel body having an inner side configured to face the wheel mount of the vehicle and an outer side configured to face outward when connected to the wheel mount of the vehicle. The present invention provides a method for forming an outer fascia layer of a molded wheel body from a second fiber composite composition comprising a second resin-injected selective fiber layup, wherein the selective fiber layup comprises at least one fiber layer covering the outer face portion of the molded wheel body, and the selective fiber layup forms a fascia layer having a configuration that cooperates with the outside of the wheel body.

[0047] The method of this second aspect of the present invention is preferably used to form a carbon fiber wheel according to the first aspect of the present invention. Therefore, all features described in relation to the first aspect are also applicable to this second aspect of the present invention.

[0048] Here too, the fascia layer can be formed / attached to the outside of the molded wheel body in several ways.

[0049] In the first embodiment, the fascia layer comprises a molded body with a cooperative shape having a configuration that cooperates with the outside of the wheel body, and the fascia layer is attached to at least a portion of the outer face and rim portions of the molded wheel body using an adhesive. The fascia layer is preferably formed in a separate step using a resin transfer molding (RTM) process and then attached to the outside of the molded wheel body from a second fiber composite composition.

[0050] In the second embodiment, the fascia layer is preferably formed on the outside of the molded wheel body by overmolding the second fiber composite composition onto at least a portion of the outer face portion of the molded wheel body. The fascia layer is preferably overmolded on the outside of the molded wheel body using a resin transfer molding (RTM) process.

[0051] Similar to the first embodiment, the fascia layer is formed on / attached to at least a portion of the outer face and / or rim portion of the wheel body.

[0052] Here again, the first resin of the wheel body and the second resin of the fascia layer can be formed from any suitable resin. The first and second resins are preferably based on unsaturated polyester, polyurethane, polyvinyl ester, epoxy, thermosetting resin, thermoplastic resin, or a combination thereof. Here again, the first resin may have a different composition from the second resin, or it may have the same or a similar composition.

[0053] In some embodiments, the second resin (as described in the first embodiment) has an aesthetically acceptable cured color. In exemplary embodiments, the first resin includes a thermal performance structural resin, preferably a high thermal performance structural resin. The thermal performance structural resin is preferably selected from at least one of epoxy, bismaleimide, polyimide, benzoxazine, phenols, cyanate esters, polyurethane, polyester, or other thermosetting materials. The second resin may include any structural resin having an aesthetically acceptable cured color. The second resin is preferably selected from at least one of epoxy, polyurethane, polyester, or vinyl ester. Again, in embodiments, the aesthetically acceptable cured color is substantially clear or transparent. The cured second resin may also be translucent, vitreous, or transparent in some forms. Again, in certain embodiments, the second resin includes a polyurethane resin, preferably a transparent polyurethane resin. The advantages of using polyurethane resins have been outlined previously and apply similarly to this second embodiment of the invention.

[0054] In some embodiments, the second resin includes a UV-resistant resin. The second resin is injected into the fibers of the fascia layer to form an aesthetic / protective surface layer. The resin and molding process steps preferably form a surface and finish that does not require any subsequent surface finishing or coating processes such as spray painting. The desired surface finish can be achieved by the molded surface design. For example, high gloss, semi-gloss, matte, textured, etc., can be applied to the molded / overmolded surface of the fascia layer using the desired textured or polished surface. Thus, in many cases, a glossy or polished surface can be achieved by using a mold for the fascia top surface having a highly polished molded surface configured to provide a final glossy finish. Therefore, the application of the fascia layer can simplify the wheel manufacturing process by eliminating timely, and potentially costly, secondary (post-molding) finishing and coating processes that may be required when the finish of the outer surface of the wheel is not acceptable or optimal. If it is necessary to create a desired surface texture using a textured or polished mold surface, the second resin is preferably a polyurethane resin.

[0055] Similar to the first embodiment, the selective fiber layup of the second fiber composition of the fascia layer may include one or more fibers (e.g., a single fiber or a mixture of two or more fibers) which are desirable to provide a specific color and pattern to the layup visible through the cured resin. It should be understood that the selective fiber layup may have any desired pattern, design or aesthetics formed from the fiber layup and any additional elements added to the layer. To form its design, the selective fiber layup may be formed from fibers selected from the group consisting of synthetic fibers such as carbon fibers, glass fibers, aluminum-processed glass fibers, aramid fibers, acrylic, polyester, PAN, PET, PE, PP, or PBO fibers; biofibers such as hemp, jute, or cellulose fibers; mineral fibers such as rock wool; metal fibers such as steel, aluminum, brass, or copper; boron fibers; or any combination thereof. In some embodiments, the selective fiber layup is preferably formed from one or more fibers selected from carbon fibers, aramid fibers or para-aramid fibers (e.g., Kevlar), glass fibers, polyester fibers, aluminum-processed glass fibers, etc. These fibers can be colored so that the selective fiber layup includes one or more fibers selected from colored glass fibers, colored polyester fibers, colored carbon fibers, and the like. Therefore, in some embodiments, the selective fiber layup includes carbon fibers having a certain amount of additional different fibers to provide decorative elements. However, in many embodiments, the selective fiber layup includes carbon fibers, or at least substantially carbon fibers.

[0056] In some embodiments, the fascia layer is formed from a second fiber composite composition comprising a carbon fiber layup into which a second resin is injected. In these embodiments, the fascia layer is typically laid up to resemble a decorative outer layer of a carbon fiber component, having a distinctive and aesthetically desirable black appearance and a regular carbon fiber layup patterning.

[0057] The fascia layer can be attached to the outside of the wheel body using various means, as described above in relation to a first aspect of the present invention. In some embodiments, the fascia is attached to the outside of the wheel body using an adhesive. The adhesive is preferably selected from at least one of epoxy, polyurethane, or methacrylate adhesives.

[0058] The fascia layer can be attached to and on the outside of the wheel body using various mounting methods. In some embodiments, the fascia layer is applied to the outside of the wheel body manually or by other means of movement (e.g., a robotic arm). Once positioned, the fascia layer can be attached to the wheel body without additional measures (e.g., by adhesive curing or drying). However, in some embodiments, pressure may be applied to at least a portion of the fascia layer to compress it to the outside of the wheel body. This pressure may be applied via compression or pressure means, or by using a mold surface or a cooperating mold.

[0059] In some embodiments, the rim portion of the molded wheel body further includes the step of forming a resin cover layer on the inner circumferential surface of the molded wheel body by a second resin having a configuration that includes the inner circumferential surface and cooperates with the inner circumferential surface of the molded wheel body.

[0060] The resin cover layer is overmolded onto the outside of the molded wheel body using a resin transfer molding (RTM) process. The resin cover layer is preferably molded to a thickness of 100 to 800 micrometers, preferably 200 to 450 micrometers, and more preferably less than 500 micrometers. In some embodiments, the resin cover layer has a thickness of 5 to 500 micrometers, more preferably 10 to 400 micrometers. In some embodiments, the resin cover layer has a thickness of 10 to 500 micrometers, more preferably 10 to 100 micrometers. Furthermore, if the second resin includes polyurethane, this embodiment can produce a finished clear coating gloss surface on the main visible surface of the composite wheel (i.e., the surface that is visible when the wheel is mounted on the wheel mount of a vehicle and is exposed to the external environment).

[0061] The fascia layer, resin cover layer, and molded body can be formed by various resin-based molding systems known in the art. The molded wheel body and fascia layer are preferably formed using a resin transfer molding (RTM) process, which is preferably a high-pressure resin injection process.

[0062] The method for forming the wheel body and fascia layer typically involves the following general steps: The steps include laying up or otherwise forming a desired shape of the wheel body or fascia layer in a cooperatively molded mold using a selected composite fiber material, The steps include providing a resin (matrix material) in contact with the layup material in the mold to form a resin introduction body, The process includes the step of curing the resin-introduced material.

[0063] The carbon fiber layup for the wheel body and the selective fiber layup for the fascia layer are preferably provided as at least one of prepregs, semipregs, woven or nonwoven fabrics, mats, preforms, pre-compacted preforms, individual fibers, tows, or towpregs or groups thereof. The fiber elements of the fiber layup for the wheel body and fascia layer can be provided as at least one fabric sheet, preferably a multiaxial fabric. In embodiments, the second fiber layup includes a carbon fiber ply of 150-300 gsm, preferably a carbon fiber ply of 200-250 gsm, more preferably a twill ply of 220 gsm. However, it should be understood that the ply can have any suitable weave or form, e.g., a plain weave ply or a twill ply. Again, it should be understood that the second fiber layup does not necessarily include, but may be formed from, one or more fibers selected from carbon fibers, aramid fibers or para-aramid fibers (e.g., Kevlar), glass fibers, polyester fibers, aluminum-processed glass fibers, etc.

[0064] The fibers and fibrous elements of the fibrous layup of the wheel body or fascia layer are preferably injected and / or impregnated with a suitable resin (as described above), and then cured, solidified, etc. The resin is preferably based on unsaturated polyester, polyurethane, polyvinyl ester, epoxy, thermosetting resin, thermoplastic resin, similar compounds, or combinations thereof. If the wheel body is formed, the resin (the first resin in the first and second embodiments of the present invention) is epoxy-based. If the fascia layer is formed, the resin (the second resin in the first and second embodiments of the present invention) is preferably polyurethane.

[0065] In some embodiments, a thermosetting powder binder is applied to the selected fiber layup in a step prior to overmolding. Preferably, the powder binder is applied to the surface of the surface ply material before the ply is cut from the roll for fiber layup.

[0066] Layup materials are typically infused with resin so that the resin permeates the material. The wheel body or fascia layer, once molded and formed into the wheel body or fascia layer, contains resin (bonding together fibers and other constituent materials). During layup (preparation up to the point before resin compaction and / or solidification, curing, etc.), the resin may not be contained within or between fiber-containing layers (e.g., prepreg or semipreg). However, the resin should form a continuous matrix after curing has occurred.

[0067] Please understand that the curing of resin and related components such as the wheel body or fascia layer includes curing, solidification, drying, or similar processes.

[0068] Various resin delivery systems can be used. In some embodiments, at least a portion of the resin is provided by resin injection and / or resin transfer molding and / or vacuum-assisted resin transfer molding. Thus, the fascia layer can be formed by various resin-based molding systems known in the art. One preferred system is resin transfer molding (RTM). In embodiments, the fascia layer comprises a resin transfer molded (RTM) part.

[0069] The fibers and fiber elements of the fiber layup of the wheel body of a carbon fiber wheel substantially consist of carbon fiber fibers. The fibers and fiber elements of the fiber layup of the fascia layer preferably substantially consist of carbon fiber fibers. However, it should be understood that a wide variety of other or alternative fibers may also be included in the fiber layup of the wheel body and fascia layer of the present invention, including but not limited to fibers selected from the group consisting of synthetic fibers such as glass fibers, aramid fibers (e.g., Kevlar), acrylic, polyester, PAN, PET, PE, PP, or PBO fibers, biofibers such as hemp, jute, or cellulose fibers, mineral fibers such as rock wool, metal fibers such as steel, aluminum, brass, or copper, boron fibers, or any combination thereof. In preferred embodiments, the fibers consist of carbon fibers, or a mixture of carbon fibers and one or more of the above fibers. The fibers may be provided in any desired orientation within the transition zone, such as unidirectional, biaxial, random, or a combination thereof. However, the fibers are preferably oriented to reduce stress between composite members and to reinforce areas of the final structure that are subjected to higher stress during use. The orientation of the fibers may or may not be the same in all layers containing fibers within the transition zone. For example, if stress analysis suggests multiaxial fiber orientation, one or more layers of fibers may be oriented differently from the others. However, in other embodiments, the fibers may be oriented substantially the same way in all layers of the fiber.

[0070] The fibrous elements may be provided in any suitable form, including prepregs, semipregs, woven or nonwoven fabrics, mats, preforms, pre-compacted preforms, individual fibers, tows, towpregs, or groups thereof. In embodiments, the fibrous elements are provided as at least one fabric sheet, preferably a multiaxial fabric. During the layup of the connection (preparation up to the point before resin compaction and / or solidification, curing, etc.), the resin may not be contained in the fiber-containing layers (e.g., prepregs or semipregs) or between the fiber-containing layers. However, the resin should form a continuous matrix after curing has occurred.

[0071] The fascia layer is configured to have a configuration that cooperates with the outside of the wheel body. The cooperative configuration is preferably a general geometric cooperation between the fascia layer and the outside of the wheel body. In this regard, the overall contours of the fascia layer and the wheel body can be designed to cooperate to help the two parts adhere together. More specifically, the inner / inner surface of the fascia layer and the overall outer contour of the wheel body are designed to cooperate and, in some cases, be complementary to help the two parts adhere together. In some embodiments, the fascia layer can be configured to cooperate with the outer face and rim portions of the wheel body, preferably by the cooperative contours of the connecting, hub, and rim portions of the wheel body.

[0072] The present invention also relates to a composite / carbon fiber wheel formed from a process according to this second aspect of the present invention. The carbon fiber wheel is preferably configured as described in the first aspect of the present invention.

[0073] It should be understood that the term “composite” as used herein means any type of composite material containing cured or uncured fibers, regardless of whether the structure is layered or not. Furthermore, cured or uncured preforms and pre-consolidated preforms are important subgroups of composite materials and composites.

[0074] It should also be understood that the term "cured" in "cured composite fiber material" indicates that the composite fiber material has undergone at least a partial curing process to harden, cure, or solidify the curable resin within the composite fiber material.

[0075] Brief explanation of the drawing The present invention will now be described with reference to the accompanying drawings illustrating specific preferred embodiments of the invention. [Brief explanation of the drawing]

[0076] [Figure 1]This is a perspective view of a carbon fiber wheel including a fascia layer attached to a carbon fiber wheel body according to one embodiment of the present invention. [Figure 2] Figure 1 shows an external cross-sectional view of the carbon fiber wheel body used in the carbon fiber wheel. [Figure 3] This is a perspective view of a carbon fiber fascia layer portion according to the first embodiment of the present invention, showing (A) the outer or upper side of the fascia portion and (B) the inner or lower side of the fascia portion. [Figure 4] These are two perspective views of the fascia layer attached to a part of the carbon fiber wheel body: (A) the fascia portion shown in Figure 3, which is aligned with the outer part of the carbon fiber wheel body shown in Figure 2, and (B) the fascia portion shown in Figure 3, which is attached to the outer part of the carbon fiber wheel body shown in Figure 2. [Figure 5] (A) A perspective view of the wheel of the carbon fiber wheel body shown in Figure 2, and (B) a more detailed view of the outer rim connection and adhesive support details of the carbon fiber wheel body. [Figure 6] Figure 2 shows an example of adhesive flow on a portion of the outer surface of a carbon fiber wheel. [Figure 7] This is an external view of the carbon fiber wheel body according to a second embodiment of the present invention. [Figure 8] Figure 7 shows the carbon fiber layup of the fascia layer placed on top of the carbon fiber wheel body. [Figure 9] This is a diagram of the resulting overmolded fascia layer on a carbon fiber wheel body according to a second embodiment of the present invention. [Figure 10] This is a diagram of the resulting overmolded fascia layer on a carbon fiber wheel body according to a third embodiment of the present invention. [Modes for carrying out the invention]

[0077] Detailed explanation Referring first to Figure 1, a perspective view is shown of a carbon fiber wheel 100 formed from a wheel body 150 and a fascia layer 200 according to one embodiment of the present invention. The illustrated overall carbon fiber wheel 100 consists of the following two main parts: A. A rim portion 102 having an annular structure to which a tire (not shown) is attached, B. Includes a circular hub 106 and a face portion 104 comprising a series of spokes 108. The hub 106 includes five fastening openings 107 (shown as fastening bolts 107A in their fixed positions in Figures 1 and 2) configured to receive fastening bolts (not shown) used to secure the wheel to a wheel mount of a vehicle (not shown). The spokes 108 have elongated arms connected at one end to the hub 106 and at the other end to the rim portion 102. In the illustrated embodiment, ten spokes 108 are shown. However, it should be understood that different numbers of spokes and spoke configurations may be used, such as five spokes, nine spokes, etc. Alternatively, the spoke portion may be replaced with a disc portion that forms a connection between the rim portion 102 and the hub 106.

[0078] It should also be understood that other carbon fiber wheel configurations incorporating the fascia layer 200 and wheel body 150 according to the present invention are also possible. For example, the carbon fiber wheel 100 may be configured as a central lock carbon fiber wheel (not shown) having a face portion including a hub 106 having a central lock opening configured to receive central lock fastening bolts (not shown) for securing the wheel to a central lock wheel mount of a vehicle (not shown).

[0079] The applicant's International Publication No. 2010 / 025495 and International Publication No. 2019 / 033169 each describe the fabrication of a composite wheel, in which the wheel is formed as a single, integrally molded part. Unlike the composite wheel taught in International Publication No. 2010 / 025495, the carbon fiber wheel 100 shown in Figure 1 is formed from two separately molded parts. Here, the molded wheel body 150 provides the structural form and elements of the wheel, while the external shape and configuration of the face portion 104 of the carbon fiber wheel 100 are provided by a molded fascia 200 attached to the outside 160 of the wheel body 150. The fascia layer 200 provides the composite wheel 100 with a desired externally facing surface shape and finish.

[0080] Figures 2 to 6 show a first embodiment of an improved carbon fiber wheel outer surface illustrating an adhesive bonding fascia embodiment of the present invention. As shown in Figures 2 to 4, the illustrated carbon fiber wheel embodiment comprises the following:

[0081] A. A wheel body 150 including a rim portion 102A having an annular structure configured to receive and seat a tire. The wheel body 150 also includes a face portion 104A having a hub 106A and spokes 108A as described above. The wheel body 150 has an inner portion 155 (including an inner barrel portion 180) configured to face a wheel mount of a vehicle (not shown) and an outer portion 160 configured to face outward when connected to a wheel mount of a vehicle (again not shown).

[0082] B. The fascia layer 200 is attached to the face portion 104A and the rim portion 102A of the outer 160 of the wheel body 150. The inner surface 250 is configured to cooperate with, cover, and engage with the outer 160 of the wheel body 150. As described above, the fascia layer 200 has an outer surface 265 that provides the external features and aesthetics of the carbon fiber wheel 100.

[0083] It should be understood that the inner barrel portion 180 includes the inner annular surface of the annular structure of the rim portion 102A, which forms the inner annular wall of the rim portion 102A of the wheel body 150.

[0084] The wheel body 150 forms the base structure of the carbon fiber wheel 100, providing the basic form and function of the carbon fiber wheel 100 through which the load is transmitted between a tire (not shown) mounted on a rim 102 and a hub 106 mounted on a vehicle wheel mount (not shown). The fascia layer 200 provides a thin aesthetic cover piece that is applied to the outer surface 160 of the wheel body 150 to provide the desired outer wheel shape and aesthetics.

[0085] The general manufacturing process for the wheel body 150 follows the same process described above for the integrally formed carbon fiber wheel 100, which is described in International Publication No. 2010 / 025495, the details of which should be understood to be incorporated herein by this reference.

[0086] The illustrated wheel body 150 (Figures 1 and 2) is intended to be formed as a single unit. This involves simultaneously injecting and / or impregnating all parts, including the rim portion 102A and the face portion 104A, with a matrix material (typically resin), which is a resin in exemplary embodiments, and then curing each part of the wheel body 150. The resin used is preferably epoxy-based. However, it should be understood that any suitable resin, such as unsaturated polyester, polyurethane, polyvinyl ester, epoxy, thermosetting resin, thermoplastic resin, similar compounds, or combinations thereof, can be used. A variety of resin delivery systems can be used, including but not limited to resin injection and / or resin transfer molding and / or vacuum-assisted resin transfer molding.

[0087] The structure of the wheel body 150 requires the use of separate rim portion molds (not shown) and face portion molds (not shown), the combination of which provides three main mold surfaces. Firstly, a surface mold oriented substantially radially with respect to the wheel's axis of rotation XX. Secondly, an inner bucket mold surface that forms the inner surface of the wheel 150. The inner bucket mold surface includes a front surface that forms the back mold wall of the face portion oriented radially with respect to the wheel's axis of rotation XX, and side walls that form the back mold wall of the rim portion axially aligned with the wheel's axis of rotation XX. Thirdly, the rim mold is substantially axially aligned with the wheel's axis of rotation XX.

[0088] In some embodiments, during use, the rim portion 102 is formed by laying up a first set of fibers embodied in a reinforcing fabric typically seated on a rim portion mold, and the face portion 104 is formed by separately laying up a second set of fibers embodied in a reinforcing fabric typically seated on a face portion mold. The reinforcing fabrics from the rim portion mold and the face portion mold are then assembled together into a combined mold, with the separate portions interconnected at the connection point where the connection between the rim portion 102 and the face portion 104 is laid up by the reinforcing material. After the connection is formed, resin is injected and / or impregnated into the respective reinforcing materials of the rim portion 102 and the face portion 104 of the wheel body 150, and then cured.

[0089] In other embodiments, it should be understood that the rim portion 102 may be formed as a laminate formed of alternating layers of hoop tow layers formed from at least one annularly wound elongated fiber tow and bias ply layers as taught in the applicant's International Publication No. 2019 / 033169, whose contents should be understood to be incorporated herein by this reference. As described in the above specification, the face portion 104 is interconnected to the rim portion 102 while laying up the rim portion 102. The fiber layup of the rim portion is also laid up after the layup of the face portion 104 is completed, so that the connection between the face portions 104 and 102 can be directly incorporated into the fiber layup of the rim portion 102. As described in International Publication No. 2019 / 033169, the face portion 104 is laid up by reinforcing members having connecting portions or tabs. The connection portion from the face portion 104 layup is laid on and within the fiber layup of the rim portion, from the rim portion to the interconnection with the face portion.

[0090] The fibrous elements of the reinforcing layup may be supplied in any suitable form, including prepregs, semipregs, woven or nonwoven fabrics, mats, preforms, pre-compacted preforms, individual fibers, tows, towpregs, or groups thereof. During the layup, the resin does not need to be contained within or between the fiber-containing layers. However, the resin should form a continuous matrix through these fibers and layers after curing.

[0091] The fascia layer 200 (see Figures 3, 4(A), and 4(B)) is configured to cover the entire surface of the outer face portion 160 and the rim portion of the wheel body 150. Thus, the fascia layer 200, more specifically the outer surface 265 of the fascia layer 200, is manufactured by all the necessary external mechanisms of the carbon fiber wheel 100 shown in Figure 1. Thus, as shown in Figure 3, the fascia layer 200 includes a substantially circular hub 104 and a cooperating central opening 110. The fascia layer 200 also includes recesses and openings 107 within the hub into which a wheel mounting device, including fastening bolts (central bolt or multiple wheel mounting bolts), is inserted (see, for example, the lower view of Figure 3(B)). In a preferred embodiment, these openings are configured to cooperate to receive the corresponding parts of the wheel mounting configuration taught in the applicant's International Publication No. 2013 / 000009 and International Publication No. 2015 / 027271. Furthermore, the fascia layer 200 (particularly its outer surface 265) includes the desired contour of the annularly spaced spokes 108.

[0092] Conversely, the outer surface 160 of the wheel body 150 may have an unfinished surface configured to be completely covered by the fascia layer 200. In this way, the wheel body 150 can be formed with simple surfaces having only basic (not detailed) geometric shapes and features. Detailed geometric shapes and features are then provided by the fascia layer 200.

[0093] The fascia layer 200 is composed of molded and contoured outer surfaces 265 having the desired finished shape of the outer surface of the carbon fiber wheel 100. In some cases, this may be a more complex geometric shape than the outer surface 160 of the wheel body 150, for example, a design feature to improve aesthetics.

[0094] Because the fascia contains much smaller, thinner molded parts (compared to bulk wheels) that allow for easier control of surface quality and finish, the components of the fascia layer 200 are designed to have an improved surface finish compared to the surface of a bulk molded carbon fiber wheel.

[0095] A portion of the fascia layer 200 is shown in Figures 3 and 4. As shown in these figures, the fascia layer 200 includes a thin molded fiber body configured to cover and mount the face portion 104A and the outward-facing rim portion 102A of the outer 160 of the wheel body 150. Therefore, the fascia layer 200 is preferably molded with a wall thickness T of 0.1 to 10 mm, and in the illustrated embodiment, 0.1 to 1 mm (best shown in Figure 3(B)). Its wall thickness is 1 / 50 to 1 / 1000 of the depth D of the wheel body 150 (typically at least 1 / 100 and 1 / 500 or less of the depth D of the wheel body 150). However, it should be understood that various wall thicknesses may be used depending on the design of the fascia layer 200 used in the wheel body 150. For example, the fascia layer 200 can be manufactured with a wall thickness of 1 to 10 mm. Other fascia layers 200 may be manufactured with a wall thickness of 0.2 to 1 mm.

[0096] The illustrated fascia layer 200 is preferably configured in a manner that is not obviously a secondary joint portion and is preferably attached / joined to the wheel body 150. As shown in Figures 4(A) and 4(B), this can be achieved by configuring the fascia layer 200 to substantially extend over the entire outer 160 of the wheel body 150 so as to cover and conceal the entire surface of the face portion 104A and the rim portion 106A of the outer 160 of the wheel body 150.

[0097] Similar to the wheel body 150, the fascia layer 200 is formed using a resin transfer molding (RTM) process. In this process, the fascia layer 200 is formed in a cooperatively shaped mold that is laid up with reinforcing materials, and then resin is injected and / or impregnated into the reinforcing materials and subsequently cured. The resulting body is a separate molded fiber composite.

[0098] As described above, the fibers in the molded fiber composite of the fascia layer 200 may include, but are not limited to, a wide variety of fibers selected from the group consisting of synthetic fibers such as carbon fibers, glass fibers, aramid fibers (e.g., Kevlar), acrylic, polyester, PAN, PET, PE, PP, or PBO fibers, biofibers such as hemp, jute, and cellulose fibers, mineral fibers such as rock wool, metal fibers such as steel, aluminum, brass, and copper, boron fibers, or any combination thereof. The selected fiber layup may have any desired pattern, design, or aesthetics formed from the fiber layup and any additional elements added to the layer, so as to be formed from one or more of the above selections of fibers. In certain embodiments, the fibers include carbon fibers, or a mixture of carbon fibers and one or more of the above fibers. In embodiments, the fibers in the molded fiber composite of the fascia layer 200 may consist substantially only of carbon fibers.

[0099] The fibrous elements of the reinforcing layup may be supplied in any suitable form, including prepregs, semipregs, woven or nonwoven fabrics, mats, preforms, pre-compacted preforms, individual fibers, tows, towpregs, or groups thereof. During the layup, the resin does not need to be contained within or between the fiber-containing layers. However, the resin should form a continuous matrix after curing.

[0100] The wheel body 150 and the fascia layer 200 may contain any suitable resin. The wheel body 150 may be formed from a first resin, and the fascia layer 200 may be formed from a second resin. The first and second resins are preferably based on unsaturated polyester, polyurethane, polyvinyl ester, epoxy, thermosetting resin, thermoplastic resin, or a combination thereof. The first and second resins may have the same or similar compositions, or alternatively, different compositions, for example, specific compositions selected to provide favorable properties for each of the wheel body 150 and fascia layer 200.

[0101] In some embodiments, the wheel body 150 can be formed using a thermal performance structural resin, preferably a high thermal performance structural resin. The thermal performance structural resin is preferably selected from at least one of epoxy, bismaleimide, polyimide, benzoxazine, phenols, cyanate esters, polyurethane, polyester, or other thermosetting materials.

[0102] In many embodiments, the fascia layer 200 is formed from any structural resin having an aesthetically acceptable cured color. This fascia resin (second resin) is preferably selected from at least one of epoxy, polyurethane, polyester, or vinyl ester. Thus, the fascia layer 200 can be used to cover any undesirable resin color used to form the wheel body 150. In this way, since the outer surface is covered with an aesthetically acceptable fascia layer 200, an aesthetically acceptable carbon fiber wheel 100 can be formed using an aesthetically unacceptable resin.

[0103] The fascia layer 200 can be attached to the wheel body 150 permanently or in a replaceable / removable manner. In the illustrated configuration, an adhesive is used to bond the fascia layer 200 to the wheel body 150. As shown in Figures 3 and 4, the molded wheel body 150, which includes a first resin-injected carbon fiber layup, is covered with a fascia layer 200 which includes a second fiber composite composition, which includes a selected fiber layup, for example, a second resin-injected carbon fiber layup. Layers of adhesive are placed between them to attach the fascia layer 200 to at least a portion of the face portion 104A and rim portion 102A of the outer 106 of the wheel body 150. The adhesive 260 is preferably selected from one of epoxy, polyurethane, or methacrylate adhesives.

[0104] The adhesive 260 can be selected to flow between the outer surface 106 of the wheel body 150 and the inner surface 250 of the fascia layer 200, filling any gaps, recesses, or cavities between them. As shown in Figures 5(A) and 5(B), the adhesive can be applied to a portion of the outer surface 160 of the wheel body 150, in this case the intersection of the hub 106A and the spokes 108A, and can be designed to flow over the outer surface 160 when the fascia layer 200 is superimposed on the wheel body 150. Figure 6(A) shows the application and formation of the adhesive over the area, and (B) shows the flow of the adhesive 260 after the fascia layer 200 has been attached to that area. The adhesive 260 flows between the outer surface 160 of the wheel body 150 and the inner surface 250 of the fascia layer 200, filling any cavities, gaps, or recesses between them. The adhesive is preferably present in an amount that completely fills the space between the wheel body 150 and the fascia layer 200. However, it should be understood that in some forms, alternative, lower-cost filler materials may replace some of the adhesive used to fill the cavities, gaps, or recesses between them.

[0105] The overall contours of the fascia layer 200 and the wheel body 150 are designed to cooperate in order to help the two parts adhere together. In this regard, in embodiments, the inner 250 of the fascia layer 200 can be molded in a cooperative geometric shape, more preferably substantially complementary to the geometric shape of the outer 160 of the wheel body 150. The inner 250 of the fascia layer 200 and the outer 160 of the wheel body 150 are generally designed complementaryly in order to cooperate in order to help the two parts adhere together.

[0106] To assist with installation, the outer surface 160 of the wheel body 150 may include recesses or contours configured to engage in cooperation with the fascia layer. As shown in Figure 5, a portion of the spokes 108A may include a contour 300 designed to receive adhesive and allow the adhesive to flow between the outer surface 160 of the wheel body 150 and the inner surface / inner 250 of the fascia layer 200.

[0107] Figures 7 to 9 show a second embodiment of the improved carbon fiber wheel outer surface illustrating an overmolded embodiment of the present invention. As shown in Figures 7 to 9, the illustrated embodiment of the carbon fiber wheel 100 comprises the following:

[0108] A. A wheel body 350 (Figure 7) including a rim portion 302A having an annular structure configured to receive and seat a tire. The wheel body 350 also includes a face portion 304A having a hub 306A and spokes 308A as described above. The wheel body 350 has an inner portion 355 configured to face a wheel mount of a vehicle (not shown) and an outer portion 360 configured to face outward when connected to a wheel mount of a vehicle (again not shown).

[0109] B. The face portion 304A and rim portion 302A of the outer 360 of the wheel body 350, and the fascia layer 400 mounted thereon. The inner surface (not shown, but the underside of the illustrated fascia layer 400) is configured to cooperate with, cover, and engage with the outer 360 of the wheel body 350. Similar to the embodiments described above, the fascia layer 400 has an outer surface 465 that provides the external features and aesthetics of the carbon fiber wheel 100.

[0110] The wheel body 350 forms the base structure of the carbon fiber wheel 100 (Figure 1), through which the load is transmitted between a tire (not shown) mounted on a rim 102 and a hub 106 mounted on a vehicle wheel mount (not shown). In this embodiment, the fascia layer 400 provides a thin aesthetic cover piece molded onto the outer 360 of the wheel body 350 to provide the desired outer wheel shape and aesthetics.

[0111] The general manufacturing process for the wheel body 350 follows the same process described above for the integrally formed carbon fiber wheel 100, as described in International Publication No. 2010 / 025495 or International Publication No. 2019 / 033169, whose contents should be understood to be incorporated herein by this reference.

[0112] As in the preceding embodiments, the illustrated wheel body 350 (Figure 7) is intended to be formed as a single unit. This involves simultaneously injecting and / or impregnating all parts, including the rim portion 302A and the face portion 304A, with a matrix material (typically resin), which in exemplary embodiments is a resin, and then curing each part of the wheel body 350. The resin used is preferably epoxy-based. However, it should be understood that any suitable resin, such as unsaturated polyester, polyurethane, polyvinyl ester, epoxy, thermosetting resin, thermoplastic resin, similar compounds, or combinations thereof, can be used. A variety of resin delivery systems can be used, including but not limited to resin injection and / or resin transfer molding and / or vacuum-assisted resin transfer molding.

[0113] The molding structure of the wheel body 350 follows the same method as described above for the wheel body 150. As described above, the rim portion 302A and the face portion 304A are typically formed by laying up a set of fibers embodied in a reinforcing fabric, which are then assembled together and placed in a combined mold into which resin is injected and / or impregnated to become the reinforcing material for the rim portion 302A and the face portion 304A of the wheel body 350, respectively, and then cured.

[0114] The fibrous elements of the reinforcing layup may be supplied in any suitable form, including prepregs, semipregs, woven or nonwoven fabrics, mats, preforms, pre-compacted preforms, individual fibers, tows, towpregs, or groups thereof. During the layup, the resin does not need to be located in or within the fiber-containing layer. However, the resin should form a continuous matrix after curing.

[0115] The fascia layer 400 (see Figures 8 and 9) is configured to cover the entire surface of the outer 360 face portion and the rim portion of the wheel body 350 (Figure 7). The outer surface 265 of the fascia layer 400 provides all the necessary external mechanisms of the wheel 100 shown in Figure 1. Thus, as shown in Figures 8 and 9, the fascia layer 200 includes a substantially circular hub 106 and a cooperating central opening 110. The fascia layer 400 also includes recesses and openings 107 within the hub into which a wheel mounting device, including fastening bolts (central bolt or multiple wheel mounting bolts), is inserted. In a preferred embodiment, these openings are configured to cooperate and receive corresponding portions of the wheel mounting configuration taught in the applicant's International Publication No. 2013 / 000009 and International Publication No. 2015 / 027271. Here again, the fascia layer 400 (particularly its outer surface 265) includes the desired contour of annularly spaced spokes 108.

[0116] As shown in Figure 7, the outer surface 360 ​​of the wheel body 350 may have an unfinished surface configured to be completely covered by the fascia layer 400. In some embodiments, the outer surface 360 ​​is manufactured without a carbon fiber cover ply, thus exposing undesirable features of the wheel body 350 structure, such as structural joints and fiber layups through the resin. Similar to the first embodiment, the wheel body 350 may be molded with a rough surface having only basic geometric shapes and features. Detailed geometric shapes and features may be included in the fascia layer 400 and / or added as contours / features to the surface of the outer surface 360 ​​of the wheel body 350.

[0117] As mentioned above, the fibers in the fascia layer 400 include, but are not limited to, a wide variety of fibers selected from the group consisting of carbon fibers, glass fibers, coated glass fibers such as aluminum-processed glass fibers, aramid fibers (such as Kevlar), synthetic fibers such as acrylic, polyester, PAN, PET, PE, PP, or PBO fibers, biofibers such as hemp, jute, and cellulose fibers, mineral fibers such as rock wool, metal fibers such as steel, aluminum, brass, and copper, boron fibers, or any combination thereof. The fibers may also be colored, for example, colored glass fibers, colored polyester fibers, colored carbon fibers, etc. The selected fiber layup can have any desired pattern, design, or aesthetics formed from the fiber layup and any additional elements added to the layer, so as to be formed from one or more of the above selections of fibers. In certain embodiments, the fibers include carbon fibers, or mixtures of carbon fibers and one or more of the above fibers. Thus, in some embodiments, the selected fiber layup includes carbon fibers having a certain amount of additional different fibers to provide decorative elements. However, in many embodiments, the selective fiber layup includes carbon fibers, or at least substantially carbon fibers. In embodiments, the fibers in the molded fiber composite of the fascia layer 400 consist substantially of carbon fibers only.

[0118] In this embodiment, the fascia layer 400 includes a fiber composite layer, such as a carbon fiber composite layer, molded onto the wheel body 350 as an overmolded carbon fiber composite layer. As shown in Figures 8 and 9, the process includes the following:

[0119] Step 1 - (As described above) The wheel body 350 is molded. For example, in one embodiment, the wheel preform 350 is manufactured using anhydrous epoxy resin from carbon fibers having 1% epoxy sizing, a 15gsm epoxy thermoplastic binder, and a 2K epoxy dicyandiamide spray tackifier. However, it should be understood that the wheel body can have a variety of different compositions as detailed above.

[0120] Once demolded from the mold (not shown), the wheel body 350 is deflashed and can then be cured (post-cured) as needed. After post-curing is complete, the outer surface 360 ​​of the wheel body 350 is typically roughened by abrasive grit blasting, for example, using aluminum oxide particles. However, it should be noted that other roughening processes such as plasma etching or laser ablation may be used, or alternative processes such as solvent washing may be used to provide similar adhesion advantages. The roughening process helps to adhere the fascia layer to this surface in subsequent steps. The wheel is then cleaned, for example, using compressed air, followed by final wiping with a lint-free cloth and an isopropyl alcohol / water solution.

[0121] Step 2 - Lay up a fascia fiber layup 370 covering at least the face portion and optionally a portion of the rim portion of the outer 360 of the wheel body 350. In the example shown in Figure 8, the fascia fiber layup 370 includes several molded carbon fiber plies, in this case twill weave plies, having a configuration that cooperates with the face portion 306A of the outer 360 of the wheel body 350. However, it should be understood that any suitable type of carbon fiber ply (or alternative fiber ply), e.g., plain weave, twill weave, etc., can be used on its outer surface, depending on the required aesthetic design. In some cases, carbon fiber plies can be used and pre-formed by heat to be applied to a predetermined position on the relevant surfaces of the face portion and rim portion of the outer 360 of the wheel body 350. Furthermore, although not shown in Figure 6, a portion of the outer rim 102 can also be covered with carbon fiber plies of the fascia fiber layup 370. In some embodiments, a tackifying adhesive (e.g., 2K epoxy dicyandiamide spray tackifier) ​​can be used to fix the fascia fiber layup 370 to the outside 360 ​​of the wheel body 350. However, it should be understood that other adhesive means, such as thermosetting powder binders, can be used for this purpose (see below). When a tackifier is used, it is preferable to use a heating tool, such as an isothermal tool, to press the layup against the wheel body 350 and to cure (typically fully cure) the 2K epoxy tackifier. The thickness of the resulting compacted and dried fiber layer of the fascia fiber layup 370 is typically about 250 micrometers.

[0122] Step 3 - The wheel body 350 covered with the fascia fiber layup 370 is placed in a cooperating mold, and resin is injected into the mold cavity so that the resin (second resin) is injected into the fascia fiber layup 370 within the range of the mold surface and the outside 360 ​​of the wheel body 350, and the resin is cured. In this regard, a cavity thickness range of 200 to 500 micrometers is preferred to provide a molded surface finish that does not require further finishing processes (if necessary), such as before an optional painting step. The tool set restricts the injected resin to only the fascia fiber layup 370 and the fascia area. In an exemplary embodiment, a face mold (not shown) for the top surface of the fascia layer 400 is a highly polished molded surface configured to provide a final glossy finish, especially when a polyurethane resin is used. In this case, no further finishing processes such as spray painting of a clear coating or other coating, polishing, etc., are required.

[0123] Therefore, in some embodiments, the second resin is injected into the fibers of the fascia layer to form an aesthetic / protective surface layer. The resin and molding process steps preferably form a surface and finish that does not require any subsequent surface finishing or coating processes such as spray painting.

[0124] The fascia layer 400 is formed on the outer 360 of the wheel body 350 by overmolding the fascia fiber layup 370 to any portion of the outer face and rim of the wheel body 350. This forms the fascia layer 400 on the outside of the wheel body 350 of a second fiber composite composition containing the fascia fiber layup 370 into which the second resin has been injected. As will be described in more detail below, the second resin has an aesthetically acceptable cured color. Thus, throughout the wheel body 350, the fascia layer 400 is formed on the wheel body 350 using a resin transfer molding (RTM) process.

[0125] Step 4 - The overmolded fascia wheel body 350 is demolded and then sent for subsequent finishing processes. In some embodiments, an external release agent is not used, as it can be added to a second resin composition used in the overmolding process.

[0126] The resulting thickness of the fascia layer is generally between 450 and 750 micrometers (250 micrometers of fiber + a coating layer of up to 500 micrometers), depending on the cavity thickness between the mold surface (not shown) and the outer surface 360 ​​of the wheel body 350. However, it should be understood that various wall thicknesses may be used depending on the design of the fascia layer 400 used on the wheel body 350. The aim of this process is to provide a fascia layer 400 that is non-porous, non-drying, free of fiber distortion, and meets the off-mold gloss / matte specifications.

[0127] The fibrous elements of the reinforcing layup may be supplied in any suitable form, including prepregs, semipregs, woven or nonwoven fabrics, mats, preforms, pre-compacted preforms, individual fibers, tows, towpregs, or groups thereof. During the layup, the resin does not need to be contained within or between the fiber-containing layers. However, the resin should form a continuous matrix through these fibers and layers after curing.

[0128] The wheel body 350 and the fascia layer 400 may contain any suitable resin. The wheel body 350 may be formed from a first resin, and the fascia layer 400 may be formed from a second resin. The first and second resins are preferably based on unsaturated polyester, polyurethane, polyvinyl ester, epoxy, thermosetting resin, thermoplastic resin, or a combination thereof.

[0129] In the embodiment, the wheel body 350 can be formed using a non-translucent colored / cured color resin. Removing the "translucent" color constraint of the structural resin used to form the wheel body 350 presents the opportunity to form a structural resin in which the structural resin used to form the wheel body 350 is, but is not limited to, a combination of one or more of the following:

[0130] · Reinforced resin, Low-cost resin, • Resins with higher elongation at break, • Higher heat-resistant resins, • Resins with shorter curing cycle times, or • Improvement of other resin mechanical properties.

[0131] Therefore, in some embodiments, the wheel body 350 can be formed using a thermal performance structural resin, preferably a high thermal performance structural resin. The thermal performance structural resin is preferably selected from at least one of epoxy, bismaleimide, polyimide, benzoxazine, phenols, cyanate esters, polyurethane, polyester, or other thermosetting materials.

[0132] The fascia layer 400 is preferably formed from any resin (second resin) having an aesthetically acceptable cured color. The second resin is preferably selected from at least one of epoxy, polyurethane, polyester, or vinyl ester. Thus, the fascia layer 400 can be used to cover any undesirable resin color used to form the wheel body 350. In this way, since the outer surface is covered with an aesthetically acceptable fascia layer 400, an aesthetically acceptable carbon fiber wheel 100 can be formed using an aesthetically unacceptable resin. As described above, an aesthetically acceptable cured color is typically a transparent or translucent color that allows the carbon fibers to be visible within the cured resin composite structure. Dedicated aesthetic / transparent fascia resins allow for the relaxation of several formulation constraints, such as Tg, which can improve other properties of the structural wheel 350, such as robustness and elongation at break.

[0133] In many embodiments, the second resin injected into the fascia ply layup in step 3 includes a UV-resistant resin.

[0134] In some embodiments, the second resin used in the fascia layer 400 includes a polyurethane resin, preferably a transparent polyurethane resin. The use of a polyurethane resin has the following advantages:

[0135] Polyurethane resins do not require protective coatings, such as those applied by spray painting. Epoxy resins require protective coatings to protect the epoxy. Therefore, additional surface finishes such as spray painting are not required. Furthermore, polyurethane resins can offer advantageous self-healing properties.

[0136] By using polyurethane resin as an alternative to spray painting, all problems related to orange peel defects that can occur when spray painting a coating to protect epoxy resin are avoided.

[0137] From a process efficiency standpoint, using polyurethane resin offers significantly faster curing times than epoxy resin, with polyurethane resins having curing cycle times of less than 4 minutes compared to epoxy resins, which typically have curing cycle times of approximately 6-10 minutes. Furthermore, polyurethane resins can contain release agents to help remove the molded wheels from the mold cavity. Epoxy resins generally require the use of external release agents.

[0138] • Improved properties - Epoxy resins can be prone to cracking when the resin thickness exceeds a threshold. Relatively, polyurethane resins are less brittle, resulting in a higher thickness threshold and thus less sensitivity to thickness. Furthermore, for relatively thicker coatings, current epoxy resins exhibit aesthetically unacceptable shrinkback. Polyurethane resins are not expected to exhibit the same defect.

[0139] • Relatively thicker polyurethane resin-rich layers are less susceptible to defects in the fibrous layer, such as raised fiber bumps. Polyurethane resin is inherently more transparent than epoxy resin.

[0140] Unlike epoxy coatings, polyurethane resin exhibits minimal or no shrinkback at coating thicknesses up to 800 micrometers.

[0141] Polyurethane resins also offer the ability to mold various surface finishes, such as high gloss, semi-gloss, matte, and textured finishes, which are influenced by the tool surface design, and the ability to achieve various opaque finishes, such as colored finishes, by adding pigments / colors to the fascia resin.

[0142] In some embodiments, no tackifying adhesive is used to secure the fascia fiber layup 370 to the outside 360 ​​of the wheel body 350. Alternatively, a thermosetting powder binder (generally epoxy-based, but with variations) can be applied to the dry fascia fiber layup 370. This powder binder may have three functions.

[0143] a. "Textile" - If the embedded powder binder helps prevent the tow from falling out of the plies that make up the fascia fiber layup 370, this tends to occur at the cut edges of the plies, which can make the layup take longer and may also result in aesthetic defects.

[0144] b. Adhesion of fascia fiber layup 370 to wheel body 350 to prevent fiber washing.

[0145] c. Pre-molding properties of fascia fiber layup 370 before layup. The overall contours of the fascia layer 400 and the wheel body 350 are designed to cooperate in order to help the two parts adhere together. In this regard, in embodiments, the inside of the fascia layer 400 can be molded in a cooperative geometric shape, more preferably substantially complementary to the geometric shape of the outside 360 ​​of the wheel body 350. The inside of the fascia layer 400 and the outside 360 ​​of the wheel body 350 are generally designed complementaryly in order to cooperate in order to help the two parts adhere together. Where necessary, design features that may be desirable to improve styling / personality / aesthetics (e.g., a bulge in front of the spoke edges of the face portion 306) can be created by using a solid insert that is retained or bonded to the outside 360 ​​of the wheel body 350. The solid insert can be manufactured using carbon fiber and resin materials, or alternatively, using less expensive materials, such as glass microsphere filling or thixotropy-filled epoxy resin. In some embodiments, less expensive filling materials can be used to completely fill the space between the wheel body and the fascia layer 400. Therefore, the wheel body 350 can be manufactured as a simpler or more common design having an overmolded fascia layer 400 with a more complex geometric shape. It should be understood that filling the space between the wheel body and the surface ply layer with filler material can be more cost-effective than using fibrous structural material.

[0146] Figure 10 shows a third embodiment of an improved carbon fiber wheel outer surface illustrating a second overmolding embodiment of the present invention. This third embodiment is an alternative embodiment to the second (overmolding) embodiment shown in Figures 7-9, in which the inner surface of the barrel 180 is also overmolded in the second overmolding process (step 3 described above) to form an overmolded inner barrel layer 480 thereon. This embodiment also preferably produces a finished transparent coating gloss surface on the main visible surface of the composite wheel 100 when the wheel is mounted on a wheel mount of a vehicle (not shown) using the overmolding process.

[0147] In this embodiment, the fascia layer 400 includes a carbon fiber composite layer molded onto the wheel body 350 as an overmolded fiber composite layer, and further includes an overmolded inner barrel surface 480 formed in the overmolding process. This process largely follows the aforementioned process shown in Figures 8 and 9, which includes the following:

[0148] Steps 1 and 2 follow the same process as described in the second embodiment above.

[0149] Step 3 - As described in the second embodiment, the fascia fiber layup coated wheel body 350 is then placed in a cooperating mold (not shown). In this case, the cooperating mold includes a resin injection space (not shown) in the mold cavity into which the fascia fiber layup is injected with resin within the mold surface and at least the face portion 104 of the wheel body 350, and the cooperating mold also includes a resin injection space in the mold cavity within the mold surface and at least the inner barrel 180 portion of the rim 102, configured to allow a resin layer to be formed on the inner barrel 180 portion of the wheel body 150. A resin, preferably a polyurethane resin in this embodiment (however, it should be understood that another second resin may be used as detailed above), is mixed, for example, by impact mixing, and high-pressure injection is used to fill the cavity and the fascia fiber layup with the resin. The resin is then cured.

[0150] Here again, the tool set is configured to restrict the injected resin to the fascia fiber layup 370 and fascia region, as well as the inner barrel 180 portion of the wheel body 150. In exemplary embodiments, a face mold (not shown) for the upper surface of the fascia layer 400 is a highly polished molded surface configured to provide a final glossy finish, particularly when polyurethane resin is used. In this case, no further finishing processes such as spray painting of a clear coating or other coating are required. A cavity thickness range of 200 to 500 micrometers is preferred to provide a molded surface finish that does not require modification.

[0151] Similar to the second embodiment, the fascia layer 400 is formed on the outer 360 of the face portion of the wheel body 350 by overmolding a fascia fiber layup 370 to any portion of the outer face portion 104 and rim portion 102 of the wheel body 350. In this embodiment, a molded resin cover layer 480 is also formed on the inner barrel 180. As will be described in more detail below, the second resin can be selected to provide the face portion 102 and the inner barrel 180 with desired properties. Thus, throughout the wheel body 350, the fascia layer 400 is formed on the wheel body 350 using a resin transfer molding (RTM) process.

[0152] Step 4 - The overmolded fascia wheel body 350 is demolded and then sent for subsequent finishing processes. Here again, in some embodiments, an external release agent is not used, as it can be added to a second resin composition used in the overmolding process.

[0153] The resulting thickness of the fascia layer is generally between 450 and 750 micrometers (250 micrometers of fibers + a coating layer of up to 500 micrometers), depending on the cavity thickness between the mold surface (not shown) and the outer surface 360 ​​of the wheel body 350. However, it should be understood that various wall thicknesses may be used depending on the design of the fascia layer 400 used on the wheel body 350.

[0154] In these embodiments, the manufacture of a separate structural wheel body, which is later overmolded with a fascia layer 400 (overmolded fascia) and a molded resin cover layer 480, enables the manufacture of an aesthetically acceptable wheel having one or more of the following: high thermal performance, improved structural performance, and low cost. As described above, the fascia layer 400 has an improved surface finish compared to the face portion beneath the wheel body. Any aesthetic defects of the structural wheel molded product are completely covered by the overmolded fascia. The process aims to provide a fascia layer 400 and a molded resin cover layer 480 that are non-porous, non-drying, free from fiber distortion, and meet off-mold gloss / matte specifications.

[0155] As described in the second embodiment, the wheel body 350 and the fascia layer 400 may contain any suitable resin. The wheel body 350 may be formed from a first resin, and the fascia layer 400 may be formed from a second resin. The first resin and the second resin are preferably based on unsaturated polyester, polyurethane, polyvinyl ester, epoxy, thermosetting resin, thermoplastic resin, or a combination thereof.

[0156] Similarly, the fascia layer 400 and the molded resin cover layer 480 are preferably formed from any resin (second resin) having an aesthetically acceptable cured color. The second resin is preferably selected from at least one of epoxy, polyurethane, polyester, or vinyl ester. In many embodiments, the second resin injected into the fascia ply layup in step 3 includes a UV-resistant resin. In a preferred embodiment of this third embodiment, the second resin used for the fascia layer 400 and the molded resin cover layer 480 includes a polyurethane resin, preferably a clear polyurethane resin. While various advantages of using polyurethane resins have been detailed above, importantly, in this embodiment, both the fascia layer 400 and the molded resin cover layer 480 can be manufactured with a final gloss finish, eliminating the need for further finishing processes such as spray painting of a clear coating or other coatings. In this regard, a clear polyurethane resin on the molded resin cover layer 480 on the inner barrel coating is applied to its surface as a protective coating. Uncoated epoxy can be eroded under weathering conditions. Therefore, in order to provide a polyurethane protective coating on epoxy resin, the epoxy needs to be coated using spray coating, for example, a clear coating, or in this case, during the molding process.

[0157] Those skilled in the art will understand that the present invention as described herein allows for modifications and alterations other than those specifically described. It will be understood that the present invention includes all such modifications and alterations that fall within the spirit and scope of the invention.

[0158] Where the terms “comprise,” “comprises,” “comprised,” or “comprising” are used herein (including in the claims), they should be interpreted as identifying the presence of a described feature, integer, step, or component, but not as excluding the presence of one or more other features, integers, steps, components, or groups thereof.

[0159] Future patent applications may be filed in Australia or abroad based on or claiming priority from this application. It should be understood that the attached provisional claims are provided as examples only and are not intended to limit the scope of what may be claimed in any such future application. Features may be added to or omitted from the provisional claims at a later date to further define or redefine one or more inventions.

Claims

1. 1. A carbon fiber wheel for a vehicle, comprising: a wheel body comprising a rim portion and a face portion, the rim portion comprising an annular structure configured to receive and seat a tire, the face portion comprising a hub configured to secure the wheel to the vehicle, and a connecting structure extending between the hub and the rim and interconnecting the hub and the rim, the wheel body having an inner side configured to face a wheel mount of a vehicle and an outer side configured to face outward when connected to the wheel mount of a vehicle, the wheel body being formed from a first carbon fiber composite composition comprising a carbon fiber layup infused with a first resin; a fascia layer attached to at least a portion of the outer face portion of the wheel body, the fascia layer being formed from a second fiber composite composition comprising a selected fiber layup infused with a second resin; and Equipped with carbon fiber wheels.

2. 2. The carbon fiber wheel of claim 1, wherein the fascia layer comprises a fiber composite layer molded to the wheel body, preferably an overmolded fiber composite layer.

3. 10. The carbon fiber wheel of claim 1, wherein the fascia layer comprises a molded fiber composite layer bonded to the wheel body, preferably bonded to the wheel body using an adhesive.

4. 10. A carbon fiber wheel according to any one of the preceding claims, wherein the fascia layer comprises a resin transfer molding (RTM) layer.

5. 10. The carbon fiber wheel according to any one of the preceding claims, wherein the first resin and the second resin are based on unsaturated polyester, polyurethane, polyvinyl ester, epoxy, thermosetting resin, thermoplastic resin, or a combination thereof.

6. 10. A carbon fiber wheel as claimed in any one of the preceding claims, wherein at least the second resin has an aesthetically acceptable cured color.

7. 10. A carbon fiber wheel according to any one of the preceding claims, wherein the second resin comprises a UV resistant resin.

8. 10. A carbon fiber wheel according to any one of the preceding claims, wherein the first resin has a different composition than the second resin.

9. A carbon fibre wheel according to any one of the preceding claims, wherein the first resin comprises a thermal performance structural resin, preferably a high thermal performance structural resin.

10. 9. The carbon fiber wheel of claim 8, wherein the thermal performance structural resin is selected from epoxy, bismaleimide, polyimide, benzoxazine, phenolic, cyanate ester, polyurethane, or polyester based resins.

11. 10. A carbon fiber wheel according to any one of the preceding claims, wherein the second resin comprises a structural resin, preferably selected from epoxy, polyurethane, polyester, vinyl ester based resins.

12. 10. The carbon fiber wheel of claim 1, wherein the selected fiber layup is formed from at least one fiber selected from carbon fiber, aramid fiber, para-aramid fiber, glass fiber, polyester fiber, aluminized glass fiber, and the like.

13. 10. A carbon fiber wheel according to any one of the preceding claims, wherein the fascia layer is formed from a second fiber composite composition comprising a carbon fiber layup infused with the second resin.

14. 10. The carbon fiber wheel of any one of the preceding claims, further comprising at least one solid insert bonded to an outer surface of the wheel body, the solid insert being configured to provide contours or features beneath the fascia layer.

15. 15. The carbon fiber wheel of claim 14, wherein the solid insert comprises a filler composition, preferably a glass microsphere filled epoxy resin body or a thixotropic filled epoxy resin body.

16. 10. A carbon fiber wheel according to any one of the preceding claims, wherein the fascia layer is defined by a shaped, contoured outer surface.

17. 10. A carbon fiber wheel according to any one of the preceding claims, wherein the fascia layer is attached to at least one of the outer face portion of the wheel body or at least a portion of the outer rim portion of the wheel body.

18. The fascia layer is the entire surface of the face portion of the outer side of the wheel body; or The entire surface of the face portion and a part of the rim portion of the outer side of the wheel body 10. A carbon fiber wheel according to any one of the preceding claims, configured to obscure at least one of:

19. 10. A carbon fiber wheel according to any one of the preceding claims, wherein the fascia layer comprises at least one fiber layer disposed over the outer face portion of the wheel body and optionally a portion of the rim portion.

20. 10. A carbon fiber wheel as claimed in any one of the preceding claims, wherein the hub of the wheel body is generally circular about a central axis and includes at least one recess, and the fascia layer is defined by a cooperating shape and at least one recess.

21. 10. A carbon fiber wheel as claimed in any one of the preceding claims, wherein the connecting structure of the wheel body includes a series of annularly spaced spokes and the fascia layer includes a series of cooperating annularly spaced spokes.

22. 22. The carbon fiber wheel of claim 21, wherein the spokes comprise elongated bodies that taper or slope inwardly from the hub toward the rim portion, and the fascia layer is configured with cooperating shapes.

23. 10. The carbon fiber wheel of any one of the preceding claims, wherein the aesthetically acceptable cured color of the second resin is at least one of substantially clear, translucent, translucent, glassy, ​​or transparent.

24. A carbon fibre wheel according to any one of the preceding claims, wherein the fascia layer comprises 150-300 gsm carbon fibre plies, preferably 200-250 gsm carbon fibre plies.

25. 10. A carbon fiber wheel according to any one of the preceding claims, wherein the fascia layer comprises at least one of a plain weave ply or a twill weave ply.

26. A carbon fiber wheel according to any one of the preceding claims, wherein the fascia layer has a thickness of 100 to 800 micrometers, preferably 200 to 750 micrometers, more preferably 450 to 750 micrometers.

27. 10. The carbon fiber wheel of claim 1, wherein the rim portion of the molded wheel body includes an inner circumferential surface, the inner circumferential surface including a resin cover layer including the second resin and configured to cooperate with the inner circumferential surface of the wheel body.

28. 28. The carbon fiber wheel according to claim 27, wherein the resin cover layer is molded to a thickness of 100 to 800 micrometers, preferably 200 to 500 micrometers, and more preferably less than 500 micrometers.

29. 1. A method of forming a carbon fiber wheel, comprising: forming a molded wheel body from a first carbon fiber composite composition including a first carbon fiber layup infused with a first resin, the molded wheel body comprising a rim portion and a face portion, the rim portion comprising an annular structure configured to receive and seat a tire, the face portion comprising a hub configured to secure the wheel to the vehicle, and a connecting structure extending between and interconnecting the hub and the rim, the wheel body having an inner side configured to face a wheel mount of a vehicle and an outer side configured to face outward when connected to the wheel mount of a vehicle; forming the outer fascia layer of the molded wheel body from a second fiber composite composition including a selected fiber layup infused with a second resin, the selected fiber layup including at least one fiber layer covering at least a portion of the face portion of the outer side of the molded wheel body, the selected fiber layup having a configuration that cooperates with the outer side of the wheel body; A method comprising:

30. 30. The method of claim 29, wherein the fascia layer is formed on the exterior of the molded wheel body by overmolding the second fiber composite composition onto at least a portion of the face portion of the exterior of the molded wheel body.

31. 31. The method of claim 30, wherein the fascia layer is overmolded onto the exterior of the molded wheel body using a resin transfer molding (RTM) process.

32. 32. The method of claim 29, 30 or 31, wherein the fascia layer is formed on at least a portion of the face portion and the rim portion of the outer side of the wheel body.

33. 30. The method of claim 29, wherein the fascia layer comprises a cooperating shaped mold having a configuration that cooperates with the exterior of the wheel body, the fascia layer being attached to at least a portion of the face portion and the rim portion of the exterior of the molded wheel body using an adhesive.

34. 34. The method of any one of claims 29 to 33, wherein the first resin and the second resin are based on unsaturated polyester, polyurethane, polyvinyl ester, epoxy, thermosetting resin, thermoplastic resin, or combinations thereof.

35. The method of any one of claims 29 to 34, wherein the first resin has a different composition than the second resin.

36. The method of any one of claims 29 to 35, wherein the second resin has an aesthetically acceptable cured color.

37. The method of any one of claims 29 to 36, wherein the second resin comprises a UV resistant resin.

38. A method according to any one of claims 29 to 37, wherein the first resin comprises a thermal performance structural resin, preferably a high thermal performance structural resin.

39. 39. The method of claim 38, wherein the thermally capable structural resin is selected from at least one of an epoxy, a bismaleimide, a polyimide, a benzoxazine, a phenolic, a cyanate ester, a polyurethane, or a polyester based resin.

40. 40. The method of any one of claims 29 to 39, wherein the second resin comprises a structural resin, preferably selected from at least one of an epoxy, polyurethane, polyester, or vinyl ester based resin.

41. 41. The method of any one of claims 29 to 40, wherein the selected fiber layup is formed from at least one fiber selected from carbon fiber, aramid fiber, para-aramid fiber, glass fiber, polyester fiber, aluminized glass fiber, and the like.

42. 42. The carbon fiber wheel of any one of claims 29 to 41, wherein the fascia layer is formed from a second fiber composite composition comprising a carbon fiber layup infused with the second resin.

43. The method of any one of claims 29 to 42, wherein a thermosetting powder binder is applied to the selected fiber lay-up in a step prior to overmolding.

44. The method of any one of claims 29 to 43, wherein the molded wheel body and fascia layer are formed using a resin transfer molding process.

45. 45. The method of any one of claims 29 to 44, wherein at least one of the first carbon fiber layup or the selected fiber layup is provided as at least one of a prepreg, semipreg, woven or nonwoven fabric, mat, preform, pre-consolidated preform, individual fiber, tow, or towpreg, or a group thereof.

46. A method according to any one of claims 29 to 45, wherein the selected fibre lay-up comprises 150 to 300 gsm carbon fibre plies, preferably 200 to 250 gsm carbon fibre plies, more preferably 220 gsm twill plies.

47. A method according to any one of claims 29 to 46, wherein the fascia layer is formed to a thickness of from 100 to 800 micrometers, preferably from 200 to 450 micrometers.

48. 48. The method of any one of claims 29 to 47, wherein the rim portion of the molded wheel body includes an inner circumferential surface, the method further comprising forming a resin cover layer on the inner circumferential surface of the molded wheel body with the second resin having a configuration that cooperates with the inner circumferential surface of the wheel body.

49. 49. The method of claim 48, wherein the resin cover layer is overmolded onto the exterior of the molded wheel body using a resin transfer molding (RTM) process.

50. 50. The method of claim 48 or 49, wherein the resin cover layer is molded to a thickness of 100 to 800 micrometers, preferably 200 to 450 micrometers, more preferably less than 500 micrometers.

51. A carbon fiber wheel formed from the process of any one of claims 29 to 50.

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