A method of manufacturing a wheel device including bonding a hub portion with lug holes and center bore hole, a spokes portion, and a barrel portion to generally form a mandrel or an inner frame of the wheel device. The inner frame is a scaled down size of the wheel device, in which a composite skin is wrapped around the inner frame to form an uncured wheel device. The uncured wheel device is encased inside a mold apparatus to cure. A cured wheel device of this method provides a wheel device with barrel, spokes, hub, lug holes and center bore hole molded into said wheel device without the use of a machine to carve out the spokes, hub, log holes or center bore hole.

Herein is disclosed a rim for a wheel. the rim comprising a barrel having first and second flanges extending radially outward from opposing edges of the barrel. and the barrel comprising a first bead seat and a second bead seat arranged axially inwardly. respectively. of the first and second flanges, wherein the barrel, and first and second flanges. comprise layers of structural fibres bound in a polymer matrix, wherein a pre-form insert is disposed between layers of the structural fibres. wherein the insert comprises a material which acts to absorb and/or deflect and/or dissipate energy from a load or impact applied axially and/or radially to a rim and/or acts to increase the hoop stiffness of the wheel and wherein the insert has, when viewed in cross-section (with the axis of the rim being parallel to the plane of the cross-section). two elongate portions. with a first elongate portion of the insert extending into one of the first or second flanges. and a second elongate portion of the insert extending underneath the first or second bead seat, respectively, such that first and second portions together form an approximate L shape in cross-section.

A manufacturing method and structure of a carbon fiber rim is revealed. A metal strip is formed by heating a metal substrate to a moldable temperature and then extruded molding. The metal strip comprises two side walls, a connecting wall and an inner rim wall to form a space surrounded by the side walls, the connecting wall, and the inner rim wall. Next, two terminals of the strip are connected to form a circle as a rim frame's embryo. The two side walls, or the two side walls and the inner rim wall of the rim frame's embryo are milled to form plural through holes and become a rim frame. Afterwards, the surface of the rim frame is roughened and covered with a trimmed carbon fiber cloth having a predetermined shape. After heatsetting and surface treating, a carbon fiber rim having a light weight and a strong structure is obtained.

A one-part wheel which is made of fiber composites without interruption of fibers with excellent mechanical properties and with low weight at the same time as well as a process for the manufacture thereof. The wheel has especially a rim well as well as a wheel disk passing over into a wheel flange of the rim well, where the wheel disk is formed at least partly by fiber layers, which run from the rim well over a wheel flange and the wheel disk. The wheel is manufactured by a multipart mold with parts displaceable at least in the axial direction. The mold is completely removed after the deposition of fibers or remains as a lost core in the wheel.

Herein is described a non-metallic rim for a wheel, the rim comprising: a barrel having first and second flanges extending radially outward from opposing edges of the barrel, and the barrel comprising a first bead seat and a second bead seat arranged axially inwardly, respectively, of the first and second flanges, wherein a primary structural component extends at least through the first flange and the barrel, the primary structural component being capable of bearing the majority of the radial and/or lateral load that, in use, would be borne by the rim a protective insert is disposed between an outer face of the first flange and the primary structural component and/or at least a portion of the first bead seat is spaced apart from the primary structural component and the primary structural component, bead seat and, if present, the protective insert are bound by a polymer matrix.

A manufacturing method and structure of a carbon fiber rim is revealed. A metal strip is formed by heating a metal substrate to a moldable temperature and then extruded molding. The metal strip comprises two side walls, a connecting wall and an inner rim wall to form a space surrounded by the side walls, the connecting wall, and the inner rim wall. Next, two terminals of the strip are connected to form a circle as a rim frame's embryo. The two side walls, or the two side walls and the inner rim wall of the rim frame's embryo are milled to form plural through holes and become a rim frame. Afterwards, the surface of the rim frame is roughened and covered with a trimmed carbon fiber cloth having a predetermined shape. After heatsetting and surface treating, a carbon fiber rim having a light weight and a strong structure is obtained.