Rim

Abstract

Provided is a rim (1) extending around a central axis to form an annular shape. The rim comprises: at least one substrate layer (10) and at least one oblique fiber layer (20). The at least one substrate layer (10) comprises at least one fiber tow (11) extending around and surrounding the central axis. The at least one oblique fiber layer (20) comprises at least one first oblique fiber layer (21, 21a), and fibers of the at least one first oblique fiber layer (21, 21a) are oriented at at least one first angle (θ1, θ1a) relative to a radial axis perpendicular to the central axis, each first angle (θ1, θ1a) ranging from ±10° to ±25°. The at least one substrate layer (10) and the at least one oblique fiber layer (20) are alternately stacked in the radial axis and are integrated into a laminated structure. The provided rim (1) has physical properties similar to or the same as those of quasi-isotropic materials, can uniformly disperse stress, and has good structural strength.

Description

rims Technical Field

[0001] The present invention relates to a wheel, and in particular to a wheel rim. Background Art

[0002] The wheel rim includes a hub, a rim, and a spoke structure for connecting the hub and the rim. The rim is used to fix a tire and extends in a ring. In addition to bearing the entire weight of the vehicle body, the rim and the tire also transmit the vehicle's transmission torque and the load between the tire and the road surface between the hub, the rim, and the spoke structure during the vehicle's movement. Traditional rims are made of metal materials. Since metal is an isotropic material, its physical properties are the same in all directions. The effect of strengthening the local structure of the rim is limited, and the rim made from it is too heavy. Therefore, composite rims made of fiber materials have been developed. Compared with metal rims, composite rims can effectively reduce rotational inertia due to their light weight, thereby allowing for more immediate control of the rim's movement. It also helps to reduce the vehicle's fuel consumption, achieving energy conservation and carbon reduction effects.

[0003] The manufacturing process for existing composite wheel rims involves stacking fiber materials and combining them with resin in a mold through hot pressing. Compared to metal, fiber materials are anisotropic, and their fiber orientation significantly influences the rim's pressure-bearing capacity and impact resistance. For example, carbon fiber unidirectional fabric exhibits superior mechanical strength when the force applied is parallel to the fabric's fiber orientation. However, when the force applied is not parallel to the fabric's fiber orientation, the fabric exhibits weak mechanical strength and is susceptible to deformation and damage.

[0004] However, the fiber orientation used in the rim of the existing composite wheel rim is still limited, and there is still a problem of insufficient mechanical strength in some stress directions. In addition, the fiber layers are overlapped with each other on the circumference of the rim in multiple sheets for easy processing, which can easily lead to fiber discontinuity, stress concentration, and easy deformation and damage, and there are shortcomings that need to be improved urgently.

[0005] Therefore, it is necessary to provide a novel and progressive rim to solve the above problems.

[0006] Summary of the Invention

[0007] The main purpose of the present invention is to provide a rim having physical properties similar to or identical to those of quasi-isotropic materials, which can evenly distribute stress and has good structural strength.

[0008] To achieve the above objectives, the present invention provides a wheel rim extending in an annular shape around a central axis, comprising: at least one substrate layer and at least one oblique fiber layer. The at least one substrate layer comprises at least one fiber tow extending and encircling the central axis; the at least one oblique fiber layer comprises at least one first oblique fiber layer, wherein the fibers of the at least one first oblique fiber layer are oriented at at least one first angle relative to a radial axis perpendicular to the central axis, each of the first angles being between ±10° and ±25°. The at least one substrate layer and the at least one oblique fiber layer are interlaced and stacked along the radial axis and integrally bonded to form a laminate structure.

[0009] Preferably, each of the first angles is in a range of ±19° to ±22°.

[0010] Preferably, the at least one oblique fiber layer includes a plurality of first oblique fiber layers, and the first angles include +22° and -22°.

[0011] Preferably, the at least one fiber bundle is spirally wound around the central axis, and each of the fiber bundles is oriented at an angle of 0 to ±10° relative to the radial axis.

[0012] Preferably, the fiber density of each oblique fiber layer is 100g / m 2 Up to 900g / m 2 .

[0013] Preferably, the fiber density of each oblique fiber layer is 250g / m 2 Up to 750g / m 2 .

[0014] Preferably, the weight ratio of the at least one substrate layer to the at least one oblique fiber layer is 35-65:65-35.

[0015] Preferably, a substrate layer is at least partially sandwiched between any two adjacent oblique fiber layers, and the fiber content of the laminate structure is 50% to 75%.

[0016] Preferably, it further comprises an inner cam edge and an outer cam edge which are arranged opposite to each other on the central axis, wherein each of the oblique fiber layers is completely laid around the central axis between the inner cam edge and the outer cam edge.

[0017] Preferably, at least one reinforcing fiber layer is further included, wherein the fibers of the at least one reinforcing fiber layer are oriented at at least one third angle relative to the radial axis, and each of the third angles is not greater than ±70° or not less than ±110°.

[0018] Preferably, each of the reinforcing fiber layers is a uniaxial fiber woven cloth, and each of the third angles is in a range of ±45° to ±70°.

[0019] Preferably, it further includes an inner cam edge, an outer cam edge and an annular recess, wherein the inner cam edge and the outer cam edge are arranged opposite to each other on the center axis, the annular recess is recessed between the inner cam edge and the outer cam edge, and at least one reinforcing fiber layer extends continuously from the outer flange toward one side of the inner flange to the annular recess.

[0020] Preferably, two annular peaks are further included on two opposite sides of the annular recess, wherein at least one of the reinforcing fiber layers extends from one side of the inner cam edge through one of the annular peaks.

[0021] Preferably, the device further comprises an inner cam edge and an outer cam edge which are arranged opposite to each other on the central axis, wherein the reinforcing fiber layer is respectively provided on two radially opposite sides of the at least one oblique fiber layer located on the inner cam edge.

[0022] Preferably, at least one decorative layer is further included, wherein the at least one decorative layer is located on at least one of an inner surface and an outer surface of the laminate structure in a radial direction.

[0023] Preferably, the at least one fiber bundle of at least one substrate layer is continuously wound around the radially outermost surface of the at least one oblique fiber layer.

[0024] Preferably, the at least one oblique fiber layer further comprises at least one second oblique fiber layer, the fibers of the at least one second oblique fiber layer are oriented at at least one second angle relative to the radial axis, and each of the second angles is ±41° to ±80°.

[0025] Preferably, each of the second angles is from ±45° to ±60°.

[0026] Preferably, the at least one oblique fiber layer further includes a plurality of second oblique fiber layers, and the second angles include +45° and -45°.

[0027] Preferably, the laminate structure is repeatedly arranged in a staggered manner in the order of one substrate layer, two first oblique fiber layers symmetrical in angle, one substrate layer, and two second oblique fiber layers symmetrical in angle.

[0028] The advantages of the present invention are:

[0029] The rim provided by the present invention has physical properties similar to or identical to those of quasi-isotropic materials, can evenly disperse stress, and has excellent structural strength. BRIEF DESCRIPTION OF THE DRAWINGS

[0030] FIG1 is a perspective view of a preferred embodiment of the present invention.

[0031] FIG2 is a cross-sectional view of a preferred embodiment of the present invention.

[0032] FIG3 is a partial enlarged view of portion A of FIG2 .

[0033] FIG4 is a partial enlarged view of portion B of FIG2 .

[0034] FIG5 is a partial enlarged view of portion C of FIG2 .

[0035] FIG6 is a schematic diagram of fiber orientation according to a preferred embodiment of the present invention.

[0036] FIG7 is a schematic diagram of fiber orientation according to another preferred embodiment of the present invention. DETAILED DESCRIPTION

[0037] The following examples are merely illustrative of possible implementations of the present invention and are not intended to limit the scope of the present invention. The words "one" or "at least one" preceding the nouns herein do not limit the quantity and may be "plural" as required. Such changes in quantity also fall within the scope of the present invention and are therefore clearly stated.

[0038] Please refer to FIG. 1 to FIG. 6 , which show a preferred embodiment of the present invention. The rim 1 of the present invention extends into a ring shape around a central axis X and includes at least one base material layer 10 and at least one oblique fiber layer 20 .

[0039] With reference to Figures 1 and 2 , the rim 1 is integrated with a hub and a spoke to form a wheel frame. The rim 1 includes an inner cam 30, an outer cam 40, and an annular recess 50, which are disposed opposite each other on the central axis X. The inner cam 30 and the outer cam 40 are disposed opposite each other on the central axis X, and the annular recess 50 is recessed between the inner cam 30 and the outer cam 40. When mounted on a vehicle body, the inner cam 30 faces the vehicle body. The rim 1 further includes two annular protrusions 60, 60a located on opposite sides of the annular recess 50. The inner cam 30, the outer cam 40, and the two annular protrusions 60, 60a are configured to engage the bead of a tire in a limited manner.

[0040] The at least one substrate layer 10 includes at least one fiber tow 11 extending and winding around the central axis X. The at least one oblique fiber layer 20 includes at least one first oblique fiber layer 21, 21a. The fibers of the at least one first oblique fiber layer 21, 21a are oriented at at least one first angle θ1, θ1a relative to a radial axis R perpendicular to the central axis X. Each of the first angles θ1, θ1a ranges from ±10° to ±25°. The at least one substrate layer 10 and the at least one oblique fiber layer 20 are interlaced and stacked along the radial axis R and integrally combined to form a laminate structure. Each of the first angles θ1, θ1a is preferably ±19° to ±22°. Through the low-angle design, the fibers of each first oblique fiber layer 21, 21a have a larger span between the inner cam edge 30 and the outer cam edge 40, which can increase the radial rigidity and impact resistance in the 90-degree direction (relative to the radial axis R). At the same time, its component force can also share the force and enhance the lateral torque shear strength.

[0041] Specifically, the at least one fiber tow 11 is spirally wound around the central axis X. Each fiber tow 11 is oriented at an angle of 0 to ±10°, preferably 0 to ±3°, relative to the radial axis R and is continuously extended and wound. Each fiber tow 11 includes a plurality of fine fiber filaments, for example, but not limited to, 3,000, 12,000, 15,000, 24,000, 48,000, or 50,000 fine fiber filaments. The plurality of fine fiber filaments can be selected from at least one of carbon fiber, glass fiber, Kevlar fiber, plant fiber, and chemical synthetic fiber, and can be selected as needed. For example, the at least one fiber tow 11 is a composite fiber filament formed by intertwining or regularly integrating carbon fiber and Kevlar fiber or other chemical synthetic fibers to form a composite fiber filament. This composite fiber filament has both the rigidity and strength of carbon fiber and the toughness of Kevlar fiber, thereby improving the toughness of the rim 1 and maintaining better integrity after impact.

[0042] The at least one oblique fiber layer 20 further includes at least one second oblique fiber layer 22, 22a. The fibers of the at least one second oblique fiber layer 22, 22a are oriented at at least one second angle θ2, θ2a relative to the radial axis R. Each second angle θ2, θ2a is preferably between ±41° and ±80°. Each second angle θ2, θ2a is preferably between ±45° and ±60°, which can resist torsional forces from the wheel hub, increase lateral rigidity, impact resistance, and biaxial torsional shear force. The component forces can also share radial forces, increasing impact resistance in the 90-degree direction (relative to the radial axis R). In this embodiment, the at least one oblique fiber layer 20 includes a plurality of first oblique fiber layers 21, 21a, and the first angles θ1, θ1a include +22° and -22°; the at least one oblique fiber layer 20 also includes a plurality of second oblique fiber layers 22, 22a, and the second angles θ2, θ2a include +45° and -45°.

[0043] Specifically, each of the oblique fiber layers 20 can be made of a two-dimensional or three-dimensional axially woven fabric (NCF fabric), a multiaxial fabric, or a fiber spread tape. Each of the first oblique fiber layers 21, 21a and each of the second oblique fiber layers 22, 22a can be, for example, unidirectional fiber fabrics. Unidirectional fiber fabrics with different fiber orientations are stacked together to provide strength and rigidity in multiple directions. In this embodiment, the at least one oblique fiber layer 20 is plural, with at least one of the oblique fiber layers 20 being the first oblique fiber layer 21 having a first angle θ1 of +22°, at least one of the oblique fiber layers 20 being the first oblique fiber layer 21a having a first angle θ1a of -22°, at least one of the oblique fiber layers 20 being the second oblique fiber layer 22 having a second angle θ2 of +45°, and at least one of the oblique fiber layers 20 being the second oblique fiber layer 22a having a second angle θ2a of -45°. In other embodiments, each of the oblique fiber layers may also be a multi-layer cloth, woven cloth or prefabricated cloth including multiple fiber orientations at the same time, such as a prefabricated cloth that is a unidirectional fiber cloth with +22° and -22° fiber orientations pre-sewn, pressed or otherwise combined into one, which can also achieve a similar effect.

[0044] Preferably, a substrate layer 10 is at least partially sandwiched between any two adjacent oblique fiber layers 20. The fiber content of the laminate structure is 50% to 75%, and the resin content (RC%) is 25% to 50%. The radial winding tension provided by the at least one fiber tow 11 thereby stabilizes the oblique fiber layers 20 and helps ensure a high fiber content and enhance the structural strength of the laminate structure. Furthermore, the at least one substrate layer 10 may be partially wound to increase thickness based on the structural features of the rim 1, forming structures such as the two annular peaks 60, 60a, the inner cam 30, and the outer cam 40.

[0045] With reference to Figures 5 and 6 , the laminate structure obtained in this embodiment is a repeated staggered arrangement of the following sequence: one substrate layer 10 (0° fiber orientation), two angularly symmetrical first oblique fiber layers 21, 21a (+22° and -22° fiber orientations), one substrate layer 10 (0° fiber orientation), and two angularly symmetrical second oblique fiber layers 22, 22a (+45° and -45° fiber orientations) until the desired thickness is achieved. This imparts a quasi-isotropic (n=6) structural characteristic to the rim 1, facilitating uniform force distribution and preventing stress concentration. It should be noted that the aforementioned laminate structure plies merely represent the order in which the plies are laid; other layers may be laid between successive layers as needed. For example, a substrate layer 10 is partially disposed between the two first oblique fiber layers 21, 21a and between the two second oblique fiber layers 22, 22a of the inner cam edge 30 and the outer cam edge 40, as shown in Figures 3 and 5, to thicken the substrate layer to form the desired geometric shape and provide a positioning effect. The first angle and the second angle may also be configured at other angles.

[0046] In other embodiments, the laminate structure may not be provided with the at least one second oblique fiber layer, but may be repeatedly staggered in the order of the base material layer 10 (0° fiber orientation), the at least one first oblique fiber layer 21 with a +22° fiber orientation, and the at least one first oblique fiber layer 21a with a -22° fiber orientation, as shown in FIG7 , which may also enable the rim 1 to have a quasi-isotropic (n=4) structural characteristic.

[0047] Furthermore, the rim 1 further includes at least one reinforcing fiber layer 70. The fibers of the at least one reinforcing fiber layer 70 are oriented at at least one third angle relative to the radial axis R. Each third angle is no greater than ±70° or no less than ±110°, thereby improving lateral bending rigidity and locally reinforcing the impact resistance of the rim 1. Each reinforcing fiber layer 70 can be, for example, a uniaxial fiber woven fabric. Each third angle is between ±45° and ±70°, preferably 70°. Specifically, at least one of the reinforcing fiber layers 70 extends continuously from the outer cam edge 40 toward one side of the inner cam edge 30 to the annular recess 50, as shown in Figures 3 and 4; at least one of the reinforcing fiber layers 70 extends from one side of the inner cam edge 30 through one of the annular peaks 60, 60a, and one of the reinforcing fiber layers 70 is respectively provided on the radially opposite sides of the at least one oblique fiber layer 20 of the inner cam edge 30, as shown in Figure 5; further, the fibers of one of the reinforcing fiber layers 70 are oriented at a positive angle, and the fibers of the other reinforcing fiber layer 70 are oriented at a negative angle, thereby providing multi-directional structural reinforcement. Thus, in addition to the lateral rigidity at different angles provided by the oblique fiber layers 20, the reinforcing fiber layers 70 also have bending rigidity and lateral impact strength different from those of the oblique fiber layers 20, especially in the areas of the inner cam edge 30 and the outer cam edge 40, effectively reinforcing the impact resistance, so that the rim 1 as a whole can more evenly distribute the force when subjected to force.

[0048] Each oblique fiber layer 20 is preferably laid completely around the central axis X between the inner cam rim 30 and the outer cam rim 40. In other words, each oblique fiber layer 20 completely covers the circumference of the rim 1 without any gaps, providing fiber continuity and excellent structural strength. The at least one fiber tow 11 of at least one base material layer 10 is continuously wound around the radially outermost surface of the at least one oblique fiber layer 20 to secure the oblique fiber layers 20. The rim 1 also includes at least one decorative layer 80, located on at least one of the radially inner and outer surfaces of the laminate structure, for enhanced aesthetics.

[0049] The fiber density of the oblique fiber layers 20 can be adjusted according to the desired number of layers, fiber material and other related parameters. The fiber density of each oblique fiber layer 20 is 100g / m 2 Up to 900g / m 2 , preferably 250g / m 2 Up to 750g / m 2 , preferably 300g / m 2 Preferably, the total fiber density of the two adjacent oblique fiber layers 20 with symmetrical angles is 600 g / m 2 The weight ratio of the at least one substrate layer 10 to the at least one oblique fiber layer 20 is 35-65:65-35, preferably 50:50.

[0050] During the manufacturing process, the at least one fiber tow 11 can be a resin-impregnated prepreg (e.g., a monofilament prepreg, Tow Preg) or dry fiber; each of the oblique fiber layers 20 and each of the reinforcing fiber layers 70 can be a resin-impregnated prepreg cloth or a resin-free dry fiber cloth. The dry fiber and the resin-free dry fiber cloth can be preformed and placed into a mold cavity. They can then be infused with resin using processes such as Resin Transfer Molding (RTM), High-Pressure Resin Transfer Molding (HP-RTM), Vacuum-Assisted Resin Transfer Molding (VARTM), and Compression Resin Transfer Molding (C-RTM), and then heated and cured to form the laminate structure. The monofilament prepreg and the resin-impregnated prepreg cloth can be preformed and then pressurized, heated, and cured in the mold cavity to form the laminate structure. The resin can be a thermosetting resin such as epoxy resin, ethylene-epoxy resin, or unsaturated resin, or / and a thermoplastic resin. The preforming method can adopt the automated fiber placement (AFP) technology to automatically wind the fiber bundles 11 according to the predetermined layer structure, lay the oblique fiber layers 20 and the reinforcing fiber layers 70, or manual laying can be adopted. At the same time, it is necessary to ensure that the oblique fiber layers 20 are continuously laid between the inner cam edge 30 and the outer cam edge 40 to help uniformly apply force and avoid stress concentration.

[0051] The above are preferred embodiments of the present invention and the technical principles used therein. For those skilled in the art, any obvious changes such as equivalent transformations, simple replacements, etc. based on the technical solution of the present invention, without departing from the spirit and scope of the present invention, are within the scope of protection of the present invention.

Claims

1. A rim, characterized in that: Extending in a ring shape around a central axis, comprising: at least one substrate layer comprising at least one fiber bundle extending and winding around the central axis; and At least one oblique fiber layer, including at least one first oblique fiber layer, wherein fibers of the at least one first oblique fiber layer are oriented at at least one first angle relative to a radial axis perpendicular to the central axis, each of the first angles being in a range of ±10° to ±25°; The at least one substrate layer and the at least one oblique fiber layer are interlaced and stacked along the radial axis and integrated into a laminate structure.

2. The rim according to claim 1, wherein: Each of the first angles is from ±19° to ±22°.

3. The rim according to claim 1, wherein: The at least one oblique fiber layer includes a plurality of first oblique fiber layers, and the first angles include +22° and -22°.

4. The rim according to claim 1, wherein: The at least one fiber bundle is spirally wound around the central axis, and each of the fiber bundles is oriented at an angle of 0 to ±10° relative to the radial axis.

5. The rim according to claim 1, wherein: The fiber density of each oblique fiber layer is 100g / m 2 Up to 900g / m 2 .

6. The rim according to claim 1, wherein: The fiber density of each oblique fiber layer is 250g / m 2 Up to 750g / m 2 .

7. The rim according to claim 1, wherein: The weight ratio of the at least one substrate layer to the at least one oblique fiber layer is 35-65:65-35.

8. The rim according to claim 1, wherein: A substrate layer is at least partially sandwiched between any two adjacent oblique fiber layers, and the fiber content of the laminate structure is 50% to 75%.

9. The rim according to claim 1, wherein: The invention also comprises an inner cam edge and an outer cam edge which are arranged opposite to each other on the central axis, wherein each of the oblique fiber layers is completely laid around the central axis between the inner cam edge and the outer cam edge.

10. The rim according to claim 1, wherein: The invention further comprises at least one reinforcing fiber layer, wherein the fibers of the at least one reinforcing fiber layer are oriented at at least one third angle relative to the radial axis, and each of the third angles is not greater than ±70° or not less than ±110°.

11. The rim according to claim 10, wherein: Each of the reinforcing fiber layers is a uniaxial fiber woven cloth, and each of the third angles is in a range from ±45° to ±70°.

12. The rim according to claim 10, wherein: It also includes an inner cam edge, an outer cam edge and an annular recess, wherein the inner cam edge and the outer cam edge are arranged opposite to each other on the central axis, the annular recess is recessed between the inner cam edge and the outer cam edge, and at least one reinforcing fiber layer extends continuously from the outer flange toward one side of the inner flange to the annular recess.

13. The rim according to claim 12, wherein: It also includes two annular peaks located on two opposite sides of the annular recess, wherein at least one of the reinforcing fiber layers extends from one side of the inner cam edge through one of the annular peaks.

14. The rim according to claim 10, wherein: The invention further comprises an inner cam edge and an outer cam edge which are arranged opposite to each other on the central axis, wherein the reinforcing fiber layer is respectively provided on two radially opposite sides of the at least one oblique fiber layer located on the inner cam edge.

15. The rim according to claim 1, wherein The invention further comprises at least one decorative layer, wherein the at least one decorative layer is located on at least one of an inner surface and an outer surface of the laminate structure in a radial direction.

16. The rim according to claim 1, wherein The at least one fiber bundle of the at least one base material layer is continuously wound around the radially outermost surface of the at least one oblique fiber layer.

17. The rim according to any one of claims 1 to 16, characterized in that The at least one oblique fiber layer further includes at least one second oblique fiber layer, wherein fibers of the at least one second oblique fiber layer are oriented at at least one second angle relative to the radial axis, and each second angle is ±41° to ±80°.

18. The rim according to claim 17, wherein: Each of the second angles is from ±45° to ±60°.

19. The rim according to claim 17, wherein: The at least one oblique fiber layer further includes a plurality of second oblique fiber layers, and the second angles include +45° and -45°.

20. The rim according to claim 17, wherein: The laminate structure is repeatedly arranged in the order of one substrate layer, two first oblique fiber layers with symmetrical angles, one substrate layer, and two second oblique fiber layers with symmetrical angles.

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