IMPROVED CARBON FIBRE WHEEL EXTERNAL FACE

Abstract

A carbon fibre vehicle wheel including a wheel body having a rim portion and a face portion, the rim portion having an annulus structure configured to receive and seat a tyre. The face portion includes a hub configured to fix the wheel to the vehicle. A connection structure extends between and interconnects the hub and the rim. The wheel body has an inner side configured to face a wheel mount of the vehicle, and an outer side configured to face outwardly when connected to the wheel mount. The wheel body embodies a first carbon fibre composite composition including a carbon fibre layup infused with a first resin, and a fascia layer attached to at least a portion of the face portion of the outer side of the wheel body. The fascia layer embodies a second fibre composite composition including a selected fibre layup infused with a second resin.

Claims

1. A carbon fibre wheel for a vehicle, the carbon fibre wheel comprising: a wheel body comprising a rim portion and a face portion, the rim portion comprises an annulus structure configured to receive and seat a tyre, the face portion including a hub configured to fix the wheel to the vehicle, and a connection structure that extends between and interconnects 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 outwardly when connected to a wheel mount of a vehicle, the wheel body being formed from a first carbon fibre composite composition comprising a carbon fibre layup infused with a first resin; and a fascia layer attached to at least a portion of the face portion of the outer side of the wheel body, the fascia layer being formed from a second fibre composite composition comprising a selected fibre layup infused with a second resin, wherein the first resin has a different composition to the second resin.

2. The carbon fibre wheel to claim 1, wherein the fascia layer comprises a fibre composite layer that is moulded to the wheel body, optionally an overmoulded fibre composite layer.

3. The carbon fibre wheel to claim 1, wherein the fascia layer comprises a moulded fibre composite layer that is adhered to the wheel body, optionally adhered to the wheel body using an adhesive.

4. The carbon fibre wheel according to claim 1, wherein the first resin and the second resin are based on unsaturated polyester, polyurethane, polyvinyl ester, epoxy, thermosets, thermoplastics, or combinations thereof.

5. The carbon fibre wheel according to claim 1, wherein at least the second resin has an aesthetically acceptable cured colour comprising at least one of: substantially clear, transparent, translucent, glassy or pellucid, and optionally having a high gloss, semi-gloss, matt, or textured surface finish.

6. The carbon fibre wheel according to claim 1, wherein the second resin comprises a UV resistant resin.

7. The carbon fibre wheel according to claim 1, wherein the first resin comprises a thermal performance structural resin, optionally a high thermal performance structural resin, optionally selected from the group consisting of: epoxys, bismaleimides, polyimides, benzoxazines, phenolics, cyanate esters, polyurethane, and polyester based resins.

8. The carbon fibre wheel according to claim 1, wherein the second resin comprises a structural resin, optionally selected from the group consisting of: epoxy, polyurethane, polyester, and vinylester based resins.

9. The carbon fibre wheel according to claim 1, wherein the selected fibre layup is formed from at least one fibre selected from the group consisting of: carbon fibre, aramid fibre, para-aramid fibre, glass fibre, polyester fibre and aluminised glass fibre.

10. The carbon fibre wheel according to claim 1, wherein the fascia layer is attached to at least one of: the face portion of the outer side of the wheel body; or at least part of the rim portion of the outer side of the wheel body.

11. A method of forming a carbon fibre wheel, comprising: forming a moulded wheel body from a first carbon fibre composite composition comprising a first carbon fibre layup infused with a first resin, the moulded wheel body comprising a rim portion and a face portion, the rim portion comprising an annulus structure configured to receive and seat a tyre, the face portion including a hub configured to fix the wheel to the vehicle, and a connection structure that extends between and interconnects 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 outwardly when connected to a wheel mount of a vehicle; forming a fascia layer on the outer side of the moulded wheel body from a second fibre composite composition comprising a selected fibre layup infused with a second resin, the selected fibre layup comprising at least one fibre layer covering at least a portion of the face portion of the outer side of the moulded wheel body, the selected fibre layup having a cooperating configuration with the outer side of the wheel body, wherein the first resin has a different composition to the second resin.

12. The method of claim 11, wherein the fascia layer is formed on the outer side of the moulded wheel body by overmoulding the second fibre composite composition onto at least a portion of the face portion of the outer side of the moulded wheel body, optionally using a resin transfer moulding (RTM) process.

13. The method of claim 11 or 12, wherein the fascia layer is formed on the face portion and at least part of the rim portion of the outer side of the wheel body.

14. The method of claim 11, wherein the fascia layer comprises a cooperatively shaped moulded body having a cooperating configuration with the outer side of the wheel body, the facia layer being attached onto the face portion and at least portion of the rim portion of the outer side of the moulded wheel body using an adhesive.

15. The method of claim 11, wherein the first resin and second resin are based on unsaturated polyester, polyurethane, polyvinyl ester, epoxy, thermosets, thermoplastics, or combinations thereof.

16. The method of claim 11, wherein the second resin has an aesthetically acceptable cured colour comprising at least one of substantially clear, transparent, translucent, glassy or pellucid, optionally having a high gloss, semi-gloss, matt, or textured surface finish.

17. The method of claim 11, wherein the second resin comprises a UV resistant resin.

18. The method of claim 11, wherein the first resin comprises a thermal performance structural resin, optionally a high thermal performance structural resin, optionally selected from at least one of epoxys, bismaleimides, polyimides, benzoxazines, phenolics, cyanate esters, polyurethane, and polyester based resins.

19. The method of claim 11, wherein the second resin comprises a structural resin, optionally selected from at least one of epoxy, polyurethane, polyester, or vinylester based resins.

20. The method according to claim 11, wherein the selected fibre layup is formed from at least one fibre selected from the group consisting of: carbon fibre, aramid fibre, para-aramid fibre, glass fibre, polyester fibre and aluminised glass fibre.

21.-51. (canceled)

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0084] The present invention will now be described with reference to the figures of the accompanying drawings, which illustrate particular preferred embodiments of the present invention, wherein:

[0085] FIG. 1 is a perspective view of a carbon fibre wheel including a facia layer attached to a carbon fibre wheel body according to one embodiment of the present invention.

[0086] FIG. 2 is a view of a section of the outer side of a carbon fibre wheel body used in the carbon fibre wheel shown in FIG. 1.

[0087] FIG. 3 provides a perspective view of a carbon fibre fascia layer section according to a first embodiment of the present invention showing: (A) The outer or top side of the fascia section; and (B) The inner or underside of the fascia section.

[0088] FIG. 4 provides two perspective views of the fascia layer section being applied to a section of the carbon fibre wheel body, showing: (A) the fascia section shown in FIG. 3 being aligned with a section of the outer side of the carbon fibre wheel body shown in FIG. 2; and (B) the fascia section shown in FIG. 3 attached to the section of the outer side of the carbon fibre wheel body shown in FIG. 2.

[0089] FIG. 5 provides (A) a perspective wheel of a carbon fibre wheel body, as shown in FIG. 2; and (B) a more detailed view of a rim connection section and adhesive assistance detail of the outer side of that carbon fibre wheel body.

[0090] FIG. 6 provides an example of adhesive flow over a section of the outer side of the carbon fibre wheel shown in FIG. 2.

[0091] FIG. 7 a view of the outer side of a carbon fibre wheel body according to a second embodiment of the present invention.

[0092] FIG. 8 provides a view of the carbon fibre layup of a fascia layer laid onto top of the carbon fibre wheel body shown in FIG. 7.

[0093] FIG. 9 provides a view of the resulting overmoulded fascia layer on the carbon fibre wheel body according to the second embodiment of the present invention.

[0094] FIG. 10 provides a view of the resulting overmoulded fascia layer on the carbon fibre wheel body according to a third embodiment of the present invention.

DETAILED DESCRIPTION

[0095] Referring firstly to FIG. 1, there is shown a perspective view of a carbon fibre wheel 100 which has been formed from a wheel body 150 and fascia layer 200 according to one embodiment of the present invention. The overall illustrated carbon fibre wheel 100 includes two main sections:

A. A rim portion 102 which comprises an annulus structure onto which a tyre (not illustrated) is mounted; and
B. A face portion 104 comprising a circular hub 106 and a series of spokes 108. The hub 106 includes five fastening apertures 107 (shown with fastening bolts 107A in place in FIGS. 1 and 2) configured to receive fastening bolts (not illustrated) used to fix the wheel to a wheel mount of a vehicle (not illustrated). The spokes 108 comprise elongate arms connected to the hub 106 at one end and the rim portion 102 at another end. Ten spokes 108 are shown in the illustrated embodiment. However, it should be appreciated that a different number of spokes and spoke configurations could be used, for example five spokes, nine spokes or the like. Alternatively, the spoke portions could be replaced with a disc/disk sections which form the connection between the rim portion 102 and the hub 106.

[0096] It should also be appreciated that other carbon fibre wheel configurations are possible that incorporate the fascia layer 200 and wheel body 150 according to the present invention. For example, the carbon fibre wheel 100 may be configured as a center lock carbon fibre wheel (not illustrated) which has a face portion that includes a hub 106 that has a center locking aperture configured to receive a center lock fastening bolt (not illustrated) to fix the wheel to a center lock wheel mount of a vehicle (not shown).

[0097] Each of the Applicant's International Patent Publications WO2010/025495A1 and WO2019/033169A1 describes the creation of a one-piece composite wheel. This forms the wheel as a single integrally moulded piece. Unlike the composite wheel taught in International Patent Publication WO2010/025495A1, the carbon fibre wheel 100 shown in FIG. 1 is formed from two separately moulded sections. Here a moulded wheel body 150 provides the structural form and elements of the wheel, whilst the external shape and configuration of the face portion 104 of the carbon fibre wheel 100 is provided by a moulded facia 200 which is attached to the outer side 160 of the wheel body 150. The fascia layer 200 provides the desired externally facing surface geometry and finish to the composite wheel 100.

[0098] FIGS. 2 to 6 illustrate a first embodiment of the improved carbon fibre wheel external face demonstrating an adhesively connected fascia embodiment of the present invention. As shown in FIGS. 2 to 4, the illustrated carbon fibre wheel embodiment comprises:

A. wheel body 150 which includes the rim portion 102A comprising an annulus structure configured to receive and seat a tyre. The wheel body 150 also includes a face portion 104A that has a hub 106A and spokes 108A as described above. The wheel body 150 has an inner side 155 (including inner barrel section 180) configured to face a wheel mount of a vehicle (not illustrated), and an outer side 160 configured to face outwardly when connected to a wheel mount of a vehicle (again not illustrated); and
B. fascia layer 200 attached onto and over the face portion 104A and the rim portion 102A of the outer side 160 of the wheel body 150. The inner face 250 is configured to cooperatively engage with and over the outer side 160 of the wheel body 150. As noted above, the fascia layer 200 has an outer face 265 that provides the external features and aesthetics of the carbon fibre wheel 100.

[0099] It should be appreciated that inner barrel section 180 comprises an inner annular surface of the annulus structure of rim portion 102A forming the inner annular wall of the rim portion 102A of the wheel body 150.

[0100] The wheel body 150 forms the base structure of the carbon fibre wheel 100, providing the basic form and function of the carbon fibre wheel 100 through which the load is transferred between a tyre (not illustrated) attached to the rim 102 and the hub 106 attached to a wheel mount (not illustrated) of a vehicle. The fascia layer 200 provides a thin aesthetic cover piece which is applied over the outer side 160 of the wheel body 150 to provide the desired external wheel geometry and aesthetics.

[0101] The general process of manufacture of the wheel body 150 follows the same process as previously described for an integrally formed carbon fibre wheel 100 described in International Patent Publication WO2010/025495A1, the contents of which are to be understood to be incorporated into this specification by this reference.

[0102] The illustrated wheel body 150 (FIGS. 1 and 2) is intended to be formed as a unitary body. This involves simultaneous injection and/or impregnation of a matrix material (typically a resin), which in the exemplary embodiment is a resin, into all parts including the rim portion 102A, and face portion 104A and then curing of each of the portions of the wheel body 150. The resin used is preferably epoxy-based. However, it should be understood that any suitable resin can be used for example unsaturated polyester, polyurethane, polyvinyl ester, epoxy, thermosets, thermoplastics, similar chemical compounds or combinations thereof. A variety of resin delivery systems can be used including, but not limited to Resin Infusion and/or Resin Transfer Moulding and/or Vacuum Assisted Resin Transfer Moulding.

[0103] The construction of a wheel body 150 necessitates use of a separate rim portion mould (not illustrated) and a face portion mould (not illustrated), the combination of which provides three main mould faces. Firstly, a face mould, which is generally radially orientated relative to the axis of rotation of the wheel X-X. Secondly, an inner bucket mould face, which forms the inside face of the wheel 150. The inner bucket mould face includes a front face forming the back mould wall of the face portion which is radially orientated relative to the axis of rotation of the wheel X-X and side walls forming the back mould wall of the rim portion that are axially aligned to the axis of rotation of the wheel X-X. Thirdly, the rim moulds are substantially axially aligned to the axis of rotation of the wheel X-X.

[0104] In some embodiments, in use, the rim portion 102 is formed by laying up a first set of fibres typically embodied in a reinforcement fabric seated in the rim portion mould, and the face portion 104 is formed by separately laying up a second set of fibres, typically embodied in a reinforcement fabric seated in the face portion mould. The reinforcement fabric from the rim portion mould and face portion mould are then assembled together in a combined mould, with the separate portions being interconnected at a connection point with the connection between the rim portion 102 and face portion 104 being laid up with reinforcement. After forming the connection, a resin is injected and/or impregnated into the reinforcement of each of the rim portion 102, the face portion 104 of the wheel body 150 and then allowed to cure.

[0105] It should be appreciated that in other embodiments, the rim portion 102 can be formed as a stacked laminate formed from alternating layers of: a hoop tow layer formed from at least one annularly wound elongate fibre tow; and a bias ply layer as taught in the Applicant's International patent publication No. WO2019/033169A1, the contents of which should be understood to be incorporated into this specification by this reference. As described in that specification, the face portion 104 is interconnected to the rim portion 102 whilst laying up the rim portion 102. The fibre layup of the rim portion is also laid up after the face portion 104 layup is completed so that the connection between the face portion 104 and 102 can be included directly in the fibre layup of the rim portion 102. As described in WO2019/033169A1, the face portion 104 is laid up with reinforcement with connection sections or tabs. The connection sections from the face portion 104 layup are laid onto and into the fibre layup of the rim portion to from the rim portion to face portion interconnection.

[0106] The fibre elements of the reinforcement layup may be provided in any suitable form including in prepregs, semi-pregs, woven or non-woven fabrics, mats, pre-forms, pre-consolidated pre-forms, individual or groups of fibres, tows, tow-pregs, or the like. During lay-up, a resin need not be comprised or located in the layers comprising fibres or between the layers comprising fibres. However, the resin should form a continuous matrix though those fibres and layers after curing.

[0107] The fascia layer 200 (see FIG. 3, 4(A) and 4(B)) is configured to cover and conceal over the entire surface of the face portion and at the rim portion of the outer side 160 of the wheel body 150. The fascia layer 200, and more particularly the outer face 265 of the fascia layer 200, is therefore produced with all the required external features of the carbon fibre wheel 100 shown in FIG. 1. As shown in FIG. 3, the fascia layer 200 therefore includes the generally circular shape of the hub 104, includes the cooperating central aperture 110. The fascia layer 200 also includes recesses and apertures 107 in the hub through which the wheel mounting arrangements, including fastening bolts (center bolt or plurality of wheel mounting bolts) are inserted (see for example the underside view in FIG. 3(B)). In preferred embodiments, these apertures are configured to cooperate and receive the corresponding sections of the wheel attachment arrangements taught in the Applicant's international patent publications WO2013/000009A1 and WO2015/027271A1. Additionally, the fascia layer 200 (and in particular the outer face 265 thereof) includes the desired contours of the annularly spaced apart spokes 108.

[0108] Conversely, the outer face 160 of the wheel body 150 can have an unfinished face which is configured to be fully covered by the fascia layer 200. In this way, the wheel body 150 can be moulded with a simple face, having only basic (not detailed) geometry and features. The detailed geometry and features are then provided by the fascia layer 200.

[0109] The fascia layer 200 is configured with a shaped and contoured outer face 265 that has the desired finished geometry of the external face of the carbon fibre wheel 100. In some cases, this may be a more complex geometry than the outer surface 160 of the wheel body 150, for example design features for improved aesthetics.

[0110] The fascia layer 200 component is designed to have an improved surface finish compared to the surface of a bulk moulded carbon fibre wheel as the fascia comprises a much smaller, thinner moulded part (compared to the bulk wheel) of which the surface quality and finish can be more controlled more easily.

[0111] A section of a fascia layer 200 is illustrated in FIGS. 3 and 4. As shown in those Figures, the fascia layer 200 comprises a thin moulded fibre body configured to be attached over and onto the face portion 104A and the outer facing rim portion 102A of the outer side 160 of the wheel body 150. The fascia layer 200 therefore is preferably moulded with a wall thickness T of from 0.1 to 10 mm, and in the illustrated embodiment between 0.1 and 1 mm (best shown in FIG. 3(B). That wall thickness being from 1/50 to 1/1000 the depth D of the wheel body 150 (typically at least 1/100 the depth D of the wheel body 150 and no more than 1/500). However, it should be appreciated that a variety of wall thickness may be used depending on the design of fascia layer 200 used on the wheel body 150. For example, a fascia layer 200 may be manufactured with a 1 to 10 mm wall thickness. Other fascia layer's 200 may be manufactured with a 0.2 to 1 mm wall thickness.

[0112] The illustrated fascia layer 200 is preferably configured and attached/bonded onto the wheel body 150 in a manner that is not obviously a secondarily bonded part. As shown in FIGS. 4(A) and 4(B), this is achieved by the fascia layer 200 being configured to extend over the entire outer side 160 of the wheel body 150 so to cover and conceal over the entire surface of the face portion 104A and at the rim portion 106A of the outer side 160 of the wheel body 150.

[0113] Like the wheel body 150, the fascia layer 200 is formed using a resin transfer moulding (RTM) process. In this process, the fascia layer 200 is formed in a cooperatively shaped mould which is laid up with reinforcement, which subsequently is injected and/or impregnated with resin, to infiltrate that reinforcement and then allowed to cure. The resulting body is a separate moulded fibre composite body.

[0114] As discussed previously, the fibre in the moulded fibre composite body of the fascia layer 200 can comprise a wide variety of fibres including but not limited to fibres selected from the group consisting of carbon fibres, glass fibres, aramid fibres (for example Kevlar), synthetic fibres such as acrylic, polyester, PAN, PET, PE, PP or PBO-fibres, or the like, bio fibres such as hemp, jute, cellulose fibres, or the like, mineral fibres for example Rockwool or the like, metal fibres for example steel, aluminium, brass, copper, or the like, boron fibres or any combination of these. The selected fibre layup can have any desired pattern, design or aesthetics formed from the fibre layup and any additional elements added to that layer, as formed from one or more of the above selection of fibres. In particular embodiments, the fibres comprise carbon fibres or a mixture of carbon fibres with one or more of the above fibres. In embodiments, the fibre in the moulded fibre composite body of the fascia layer 200 substantially only comprises carbon fibre.

[0115] The fibres elements of the reinforcement layup may be provided in any suitable form including in prepregs, semi-pregs, woven or non-woven fabrics, mats, pre-forms, pre-consolidated pre-forms, individual or groups of fibres, tows, tow-pregs, or the like. During lay-up, a resin need not be comprised or located in the layers comprising fibres or between the layers comprising fibres. However, the resin should form a continuous matrix after curing.

[0116] The wheel body 150 and fascia layer 200 can include any suitable resin. The wheel body 150 can be formed from a first resin and the fascia layer 200 can be formed from a second resin. Each of the first and second resins is preferably based on unsaturated polyester, polyurethane, polyvinyl ester, epoxy, thermosets, thermoplastics, or combinations thereof. The first resin and second resin can have the same or similar compositions, or alternatively could have different compositions, for example, specific compositions selected to provide advantageous properties to the respective wheel body 150 and fascia layer 200.

[0117] 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 epoxys, bismaleimides, polyimides, benzoxazines, phenolics, cyanate esters, polyurethane, polyester or other thermoset materials.

[0118] In many embodiments, the fascia layer 200 is formed from any structural resin having an aesthetically acceptable cured colour. This fascia resin (second resin) is preferably selected from at least one of epoxy, polyurethane, polyester, or vinylester. The fascia layer 200 can therefore be used to cover undesirable resin colours used to form the wheel body 150. This way an aesthetically acceptable carbon fibre wheel 100 can be formed using an aesthetically unacceptable resin, as the outer surface is covered with the aesthetically acceptable fascia layer 200.

[0119] The fascia layer 200 can be attached to the wheel body 150 in a permanent or in a replaceable/removable manner. In the illustrated arrangement, an adhesive is used to bond the fascia layer 200 to the wheel body 150. As shown in FIGS. 3 and 4, a moulded wheel body 150 comprising a carbon fibre layup infused with a first resin, is overlaid with a fascia layer 200 comprising a second fibre composite composition comprising a selected fibre layup, for example a carbon fibre layup, infused with a second resin. A layer of adhesive is placed therebetween to attach the fascia layer 200 onto the face portion 104A and at least portion of the rim portion 102A of the outer side 106 of the wheel body 150. The adhesive 260 is preferably selected from one of an epoxy, a polyurethane, or a methacrylate adhesive.

[0120] The adhesive 260 can be selected to be able to flow between the outer side 106 of the wheel body 150 and an inner surface 250 of the fascia layer 200 to fill any gaps, recesses or cavities therebetween. As shown in FIG. 5(A) and (B), adhesive can be applied to sections of the outer surface 160 of the wheel body 150, in this case at the intersection of the hub 106A and spokes 108A and be designed to flow over the outer surface 160 when the fascia layer 200 is overlaid onto the wheel body 150. FIG. 6 shows (A) the application formation of adhesive on that area, and (B) the flow of the adhesive 260 after application of the fascia layer 200 onto that area. The adhesive 260 flows and between the outer side 160 of the wheel body 150 and an inner surface 250 of the fascia layer 200 to fill any cavity, gap or recess therebetween. The adhesive is present in an amount that preferably completely fills the space between the wheel body 150 and fascia layer 200. It should be appreciated however that in some forms, an alternative, lower cost filler material could substitute some of the adhesive used in filling the cavity, gaps or recesses therebetween.

[0121] The general contours of the fascia layer 200 and wheel body 150 are designed to cooperate to assist attachment of the two portions together. In this respect, the inner side 250 of the fascia layer 200 can be moulded with a geometry that cooperates, and more preferably is generally complementary to the geometry of the outer side 160 of the wheel body 150. The general contours of the inner side 250 of the fascia layer 200 and outer side 160 of the wheel body 150 are generally complementarily designed to cooperate to assist attachment of the two portions together.

[0122] To assist in attachment, the outer side 160 of the wheel body 150 can include recesses or contours configured to cooperatively engage with the fascia layer. As shown in FIG. 5, a section of the spoke 108A can include a contour 300 designed to receive adhesive and allow that adhesive to flow between the outer side 160 of the wheel body 150 and an inner surface/side 250 of the fascia layer 200.

[0123] FIGS. 7 to 9 illustrate a second embodiment of the improved carbon fibre wheel external face demonstrating an overmoulded embodiment of the present invention. As shown in FIGS. 7 to 9, the illustrated carbon fibre wheel 100 embodiment comprises:

A. wheel body 350 (FIG. 7) which includes the rim portion 302A comprising an annulus structure configured to receive and seat a tyre. The wheel body 350 also includes a face portion 304A that has a hub 306A and spokes 308A as described above. The wheel body 350 has an inner side 355 configured to face a wheel mount of a vehicle (not illustrated), and an outer side 360 configured to face outwardly when connected to a wheel mount of a vehicle (again not illustrated); and
B. fascia layer 400 attached onto and over the face portion 304A and the rim portion 302A of the outer side 360 of the wheel body 350. The inner face (not illustrated in the Figures, but the underside of the illustrated fascia layer 400) is configured to cooperatively engage with and over the outer side 360 of the wheel body 350. As with the previous embodiment, the fascia layer 400 has an outer face 465 that provides the external features and aesthetics of the wheel 100.

[0124] The wheel body 350 forms the base structure of the carbon fibre wheel 100 (FIG. 1), providing the basic form and function of the carbon fibre wheel 100 through which the load is transferred between a tyre (not illustrated) attached to the rim 102 and the hub 106 attached to a wheel mount (not illustrated) of a vehicle. In this embodiment, the fascia layer 400 provides a thin aesthetic cover layer which is moulded over the outer side 360 of the wheel body 350 to provide the desired external wheel geometry and aesthetics.

[0125] The general process of manufacture of the wheel body 350 follows the same process as previously described for an integrally formed carbon fibre wheel 100, following as described in International Patent Publication WO2010/025495A1 or in International patent publication No. WO2019/033169A1, again the contents of which are to be understood to be incorporated into this specification by this reference.

[0126] As in the previous embodiment, the illustrated wheel body 350 (FIG. 7) is intended to be formed as a unitary body. This involves simultaneous injection and/or impregnation of a matrix material (typically a resin), which in the exemplary embodiment is a resin, into all parts including the rim portion 302A, and face portion 304A and then curing of each of the portions of the wheel body 350. The resin used is preferably epoxy-based. However, it should be understood that any suitable resin can be used for example unsaturated polyester, polyurethane, polyvinyl ester, epoxy, thermosets, thermoplastics, similar chemical compounds or combinations thereof. A variety of resin delivery systems can be used including, but not limited to Resin Infusion and/or Resin Transfer Moulding and/or Vacuum Assisted Resin Transfer Moulding.

[0127] The moulded construction of a wheel body 350 follows the same method as described for wheel body 150 above. As described above, the rim portion 302A and the face portion 304A is formed by laying up a set of fibres, typically embodied in a reinforcement fabric which are then assembled together and located into a combined mould, into which a resin is injected and/or impregnated into the reinforcement of each of the rim portion 302A, the face portion 304A of the wheel body 350 and then allowed to cure.

[0128] The fibre elements of the reinforcement layup may be provided in any suitable form including in prepregs, semi-pregs, woven or non-woven fabrics, mats, pre-forms, pre-consolidated pre-forms, individual or groups of fibres, tows, tow-pregs, or the like. During lay-up, a resin need not be located in the layers comprising fibres or between the layers comprising fibres. However, the resin should form a continuous matrix after curing.

[0129] The fascia layer 400 (see FIGS. 8 and 9) is configured to cover and conceal over the entire surface of the face portion and at the rim portion of the outer side 360 of the wheel body 350 (FIG. 7). The outer face 265 of the fascia layer 400 provides all the required external features of the wheel 100 shown in FIG. 1. As shown in FIGS. 8 and 9, the fascia layer 200 therefore includes the generally circular shape of the hub 106, includes the cooperating central aperture 110. The fascia layer 400 also includes the recesses and apertures 107 in the hub through which the wheel mounting arrangements, including fastening bolts (center bolt or plurality of wheel mounting bolts) are inserted. In preferred embodiments, these apertures are configured to cooperate and receive the corresponding sections of the wheel attachment arrangements taught in the Applicant's international patent publications WO2013/000009A1 and WO2015/027271A1. Again, the fascia layer 400 (and in particular the outer face 265 thereof) includes the desired contours of the annularly spaced apart spokes 108.

[0130] As shown in FIG. 7, the outer face 360 of the wheel body 350 can have an unfinished face which is configured to be fully covered by the fascia layer 400. In some embodiments, that outer face 360 is produced without a cover ply of carbon fibre, thus revealing undesirable features of the wheel body 350 structure, such as constructional joins and fibre layup through the resin. As with the first embodiment, the wheel body 350 can be moulded with a rough face, with only basic geometry and features. The detailed geometry and features can be included in the fascia layer 400 and/or added as contours/features to the surface of the outer face 360 of the wheel body 350.

[0131] As discussed previously, the fibre in the fascia layer 400 can comprise a wide variety of fibres including but not limited to fibres selected from the group consisting of carbon fibres, glass fibres, coated glass fibres such as aluminised glass fibres, aramid fibres (such as Kevlar), synthetic fibres such as acrylic, polyester, PAN, PET, PE, PP or PBO-fibres, or the like, bio fibres such as hemp, jute, cellulose fibres, or the like, mineral fibres for example Rockwool or the like, metal fibres for example steel, aluminium, brass, copper, or the like, boron fibres or any combination of these. The fibres may also be coloured for example coloured glass fibres, coloured polyester fibres, coloured carbon fibres or the like. The selected fibre layup can have any desired pattern, design or aesthetics formed from the fibre layup and any additional elements added to that layer, as formed from one or more of the above selection of fibres. In particular embodiments, the fibres comprise carbon fibres or a mixture of carbon fibres with one or more of the above fibres. Thus, in some embodiments, the selected fibre layup comprises carbon fibres with an amount of additional different fibres to provide a decorative element. However, in many embodiments, the selected fibre layup comprises carbon fibres or at least substantially comprise carbon fibres. In embodiments, the fibre in the moulded fibre composite body of the fascia layer 400 substantially only comprise carbon fibre.

[0132] In this embodiment, the fascia layer 400 comprises a fibre composite layer, for example a carbon fibre composite layer, that is moulded to the wheel body 350 as an overmoulded carbon fibre composite layer. As shown in FIGS. 8 and 9, the process involves:

[0133] STEP 1—Moulding a wheel body 350 (as described above).

[0134] For example, in one embodiment the wheel preform 350 is manufactured from: carbon fibre with 1% epoxy based sizing, 15 gsm epoxy thermoplastic binder, 2K epoxy dicyandiamide spray tackifier, using an Anhydride epoxy resin. However, it should be appreciated that the wheel body could have a variety of different compositions as detailed previously.

[0135] Once demoulded from the mould (not illustrated), the wheel body 350 can be de-flashed and then if required, left to cure (post-curing). Once post-curing has been completed, the outer face surface 360 of the wheel body 350 is roughened, typically by abrasively grit blasting that surface, for example using aluminium oxide particles. However, it should be appreciated that other roughening processes such as plasma etching or laser ablation could be used, or alternate processes such as a solvent cleaning process could be used to provide similar adhering advantages. The roughening process assists with adhering the fascia layer to this surface in subsequent steps. The wheel is then cleaned, for example using compressed air followed by a final wipe with a lint free cloth and solution of isopropyl alcohol/water.

[0136] STEP 2—Laying up a fascia fibre layup 370 covering at least the face portion and optionally a portion of the rim portion of the outer side 360 of the wheel body 350. In the example illustrated in FIG. 8, the fascia fibre layup 370 comprises a number of shaped carbon fibre plies, in this case a twill weave ply, having a cooperating configuration with the face section 306A of the outer side 360 of the wheel body 350. It should however, be appreciated that any suitable type of carbon fibre ply (or alternative fibre ply) could be used, for example plain weave, twill weave, or the like depending on the required aesthetic design required for that external face. In some instances, carbon fibre plies can be used, and preformed to shape through heating for application in position on the relevant surfaces of the face portion and rim portion of the outer side 360 of the wheel body 350. Moreover, whilst not illustrated in FIG. 6, a portion of the outer rim 102 could also be covered with carbon fibre plys of the fascia fibre layup 370. In some embodiments, a tackifier adhesive (for example 2K epoxy dicyandiamide spray tackifier) can be used to fix the fascia fibre layup 370 onto the outer side 360 of the wheel body 350. However, it should be appreciated that other adhesive means for example a thermoset powder binder could be used for this purpose (see below). Where a tackifier is used, it is preferred for a heated tool, such as an isothermal tool, to be used to press the layup against the wheel body 350 and cure (typically fully cure) the 2K epoxy tackifier. The resulting consolidated dry fibre layer thickness of the fascia fibre layup 370 is typically around 250 microns.

[0137] STEP 3—placing the fascia fibre layup 370 covered wheel body 350 into a cooperating mould, injecting resin into the cavity of the mould such that the fascia fibre layup 370 is infused with resin (the second resin) within the confines of the mould face and the outer side 360 of the wheel body 350, and allowing the resin to cure. In this respect, a cavity thickness range of 200 to 500 microns is preferred to provide a moulded surface finish that requires no rectification prior to further finishing processes (if required) for example an optional painting step. The toolset restricts injected resin to fascia fibre layup 370 and fascia region only. In exemplary embodiments, the face mould (not illustrated) for the top surface of the fascia layer 400 is a highly polished, moulded surface configured to provide a final glossy finish, particularly when a polyurethane resin is used. In this case, no further finishing process such a spray painting a clear coating or other coating, polishing or the like is required.

[0138] Thus, in some embodiments the second resin is infused into the fibre of the fascia layer creating an aesthetic/protective surface layer. The resin and forming process step preferably forms a surface and finish which does not require any subsequent surface finishing or coating processes such as spray painting.

[0139] The fascia layer 400 is formed on the outer side 360 of the wheel body 350 by overmoulding the fascia fibre layup 370 onto the face portion and an optional portion of the rim portion of the outer side of the wheel body 350. This forms a facia layer 400 on the outer side of the wheel body 350 of a second fibre composite composition comprising the fascia fibre layup 370 infused with a second resin. As described in more detail below, that second resin having an aesthetically acceptable cured colour. Thus, overall the wheel body 350, the fascia layer 400 is formed on the wheel body 350 using a resin transfer moulding (RTM) process.

[0140] STEP 4—The overmoulded fascia wheel body 350 is demoulded and then sent for subsequent finishing processing. In some embodiments, no external release agent is used as this can be added into the second resin composition used in the overmoulding process.

[0141] The resulting thickness of the fascia layer is generally between 450 to 750 microns (250 microns fibre plus up to 500 microns coating layer) depending on the cavity thickness between the mould face (not illustrated) and the outer side 360 of the wheel body 350. However, it should be appreciated that a variety of wall thickness may be used depending on the design of fascia layer 400 used on the wheel body 350. The process aims to provide a fascia layer 400 that has no porosity, no dryness; no fibre distortion; meets gloss/matte specifications out of mould.

[0142] The fibres elements of the reinforcement layup may be provided in any suitable form including in prepregs, semi-pregs, woven or non-woven fabrics, mats, pre-forms, pre-consolidated pre-forms, individual or groups of fibres, tows, tow-pregs, or the like. During lay-up, a resin need not be comprised or located in the layers comprising fibres or between the layers comprising fibres. However, the resin should form a continuous matrix though those fibres and layers after curing.

[0143] The wheel body 350 and fascia layer 400 can include any suitable resin. The wheel body 350 can be formed from a first resin and the fascia layer 400 can be formed from a second resin. Each of the first and second resins is preferably based on unsaturated polyester, polyurethane, polyvinyl ester, epoxy, thermosets, thermoplastics, or combinations thereof.

[0144] In embodiments, the wheel body 350 can be formed using a non-translucent coloured/cured colour resin. The removal of the ‘translucent’ colour constraint in the structural resin used in forming the wheel body 350 creates formulation opportunities for the structural resin not limited to and possibly combinations of one or more of:

[0145] Tougher resin;

[0146] Lower cost resin;

[0147] Higher elongation to failure resin;

[0148] Higher Thermal performance resin;

[0149] Shorter cure cycle time resin; or

[0150] Other resin mechanical property improvements.

[0151] Thus, 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 epoxys, bismaleimides, polyimides, benzoxazines, phenolics, cyanate esters, polyurethane, polyester or other thermoset materials.

[0152] The fascia layer 400 is preferably formed from any resin (second resin) having an aesthetically acceptable cured colour. The second resin is preferably selected from at least one of epoxy, polyurethane, polyester, or vinylester. The fascia layer 400 can therefore be used to cover undesirable resin colours used to form the wheel body 350. This way an aesthetically acceptable carbon fibre wheel 100 can be formed using an aesthetically unacceptable resin, as the outer surface is covered with the aesthetically acceptable fascia layer 400. As discussed above, an aesthetically acceptable cured colour is typically a clear or translucent colour which enables the carbon fibre to be seen within the cured resin composite structure. A dedicated aesthetic/clear fascia resin allows relaxation of some formulation constraints—for example Tg, which enables other properties of the structural wheel 350 to be improved, for example toughness and elongation to failure.

[0153] In many embodiments, the second resin infused into the fascia ply layup in step 3 comprises a UV resistant resin.

[0154] In some embodiments, the second resin used for the fascia layer 400 comprise a polyurethane resin, and preferably a clear polyurethane resin. The use of a polyurethane resin has the following advantages:

[0155] Polyurethane resin does not require a protective coating, applied for example by spray painting. Epoxy resin requires a protective coating to protect the epoxy. Thus, no additional surface finishing such as spray-painting is required. In addition, a polyurethane resin can provide an advantageous self-healing functionality.

[0156] Using polyurethane resin as an alternative to spray painting avoids any issues with orange peel defects that can occur when spray painting coatings to protect epoxy resin.

[0157] In terms of process efficiencies, using a Polyurethane resin has a much faster cure time than epoxy resins, with polyurethane resins having a cure cycle time of less than 4 mins compared to epoxy resin with cure cycle time of ˜6 to 10 minutes. Furthermore, polyurethane resins can include a release agent to assist in removal of the moulded wheel from a mould cavity. Whereas epoxy resins generally require use of an external release agent.

[0158] Improved properties—epoxy resin can be susceptible to cracking if the resin thickness exceeds a threshold. Relatively, a polyurethane resin is comparatively less brittle so has a higher thickness threshold, i.e. it will be less sensitive to thickness. Moreover, for relatively thicker coatings, the current epoxy resin shows shrink back which is not acceptable, aesthetically. Polyurethane resin is not expected to show the same defect.

[0159] The relatively thicker polyurethane resin rich layer is less susceptible to defects in the fibre layer such as raised fibrous bumps. Polyurethane resin is inherently clearer than epoxy resin.

[0160] Polyurethane resin provides minimal to no shrink-back in coating thicknesses up to 800 micron, unlike epoxy-based coatings.

[0161] Polyurethane resin also provides the ability to mould a variety of surface finishes, affected by tooling surface design, for example high Gloss, semi-gloss, matt, textured etc. and the ability to achieve a variety of non-clear finishes by adding pigment/colours to the Fascia resin, for example tinted finish.

[0162] In some embodiments, no tackifier adhesive is used to fix the fascia fibre layup 370 onto the outer side 360 of the wheel body 350. A thermoset powder binder (generally epoxy based but there are variations) could alternatively be applied to the dry fascia fibre layup 370. This powder binder has possibly three functions:

a. ‘Weaveset’—where the embedded powder binder assists in preventing tows from falling out of the ply making up the fascia fibre layup 370—this tends to occur at the cut edges of the ply and can make layup time consuming and also cause aesthetic defects.
b. Adhesion of the fascia fibre layup 370 to the wheel body 350—to prevent fibre wash.
c. Preformability of the fascia fibre layup 370 prior to layup.

[0163] The general contours of the fascia layer 400 and wheel body 350 are designed to cooperate to assist attachment of the two portions together. In this respect, the inner side of the fascia layer 400 can be moulded with a geometry that cooperates, and more preferably is generally complementary to the geometry of the outer side 360 of the wheel body 350. The general contours of the inner side of the fascia layer 400 and outer side 360 of the wheel body 350 are generally complementarily designed to cooperate to assist attachment of the two portions together. Where required, features in the design (for example ridges on front of spoke edges of the face portion 306) that may be desirable to improve styling/character/aesthetics can be created via the use of solid inserts tacked or bonded to the outer side 360 of the wheel body 350. Solid inserts may be manufactured using carbon fibre and resin material, or alternatively a less expensive material for example glass microsphere filled or thixotropic filled epoxy resin. In some embodiments, lower cost filler materials could be used to completely fill the space between the wheel body and the fascia layer 400. The wheel body 350 can be therefore by produced as a simpler or generic design with the overmoulded fascia layer 400 having a more complicated geometry. It should be appreciated that it can be more cost effective to fill between the wheel body and the surface ply layer using a filler material than it is to use a fibrous structural material.

[0164] FIG. 10 illustrates a third embodiment of the improved carbon fibre wheel external face demonstrating a second overmoulded embodiment of the present invention. This third embodiment is an alternative embodiment to the second (overmoulded) embodiment illustrated in FIGS. 7 to 9 in which the internal surface of the barrel 180 is also overmoulded in the second overmoulding process—Step 3 described above—to form an overmoulded inner barrel layer 480 thereon. This embodiment also preferably produces a finished clear coated glossy surface on the main visible surfaces of the composite wheel 100 when that wheel is mounted on a wheel mount of a vehicle (not illustrated) using the overmoulding process.

[0165] In this embodiment, the fascia layer 400 comprises a carbon fibre composite layer that is moulded to the wheel body 350 as an overmoulded fibre composite layer, and additionally includes an overmoulded inner barrel surface 480 formed in the overmoulding process. The process largely follows the previously described process shown in FIGS. 8 and 9 involving:

[0166] STEP 1, and STEP 2 follow the same process as described for the second embodiment above.

[0167] STEP 3—As described for the second embodiment, the fascia fibre layup covered wheel body 350 is then placed into a cooperating mould (not illustrated). In this case, the cooperating mould includes a resin infusion space in the mould cavity (not illustrated) where the fascia fibre layup is infused with resin within the confines of the mould face and the at least the face portion 104 of the wheel body 350, and also a resin infusion space in the mould cavity within the confines of the mould face and the at least the inner barrel 180 section of the rim 102 which is configured to enable a resin layer to be formed over the inner barrel 180 section of the wheel body 150. The resin, preferably a polyurethane resin in this embodiment (though it should be appreciated that another second resin could be used as detailed previously) is mixed, for example impingement mixed, and high-pressure injection is used to fill the cavities and fascia fibre layup with that resin. The resin is then allowed to cure.

[0168] Again, the toolset is configured to restrict injected resin to fascia fibre layup 370 and fascia region, as well as the inner barrel 180 section of the wheel body 150. In exemplary embodiments, the face mould (not illustrated) for the top surface of the fascia layer 400 is a highly polished, moulded surface configured to provide a final glossy finish, particularly when a polyurethane resin is used. In this case, no further finishing process such a spray painting a clear coating or other coating is required. A cavity thickness range of 200 to 500 microns is preferred to provide a moulded surface finish that requires no rectification.

[0169] As with the second embodiment, the fascia layer 400 is formed on the outer side 360 of the face portion wheel body 350 by overmoulding the fascia fibre layup 370 onto the face portion 104 and an optional portion of the rim portion 102 of the outer side of the wheel body 350. In this embodiment, a moulded resin cover layer 480 is also formed on the inner barrel 180. As described in more detail below, that second resin can be selected to provide desired properties to the face portion 102 and inner barrel 180. Thus, overall the wheel body 350, the fascia layer 400 is formed on the wheel body 350 using a resin transfer moulding (RTM) process.

[0170] STEP 4—The overmoulded fascia wheel body 350 is demoulded and then sent for subsequent finishing processing. Again, in some embodiments, no external release agent is used as this can be added into the second resin composition used in the overmoulding process.

[0171] The resulting thickness of the fascia layer is generally between 450 to 750 microns (250 microns fibre plus up to 500 microns coating layer) depending on the cavity thickness between the mould face (not illustrated) and the outer side 360 of the wheel body 350. However, it should be appreciated that a variety of wall thickness may be used depending on the design of fascia layer 400 used on the wheel body 350.

[0172] In these embodiments, the production of a separate structural wheel body which is then overmoulded with fascia layer 400 (overmoulded fascia) and the moulded resin cover layer 480 enables the production of an aesthetically acceptable wheel with one or more of high thermal performance, improved structural performance, and reduced cost. As above, the fascia layer 400 has improved surface finish compared to the underlying face portion of the wheel body. Any aesthetic defects on the structural wheel moulding are completely covered by the overmoulded fascia. The process aims to provide a fascia layer 400 and moulded resin cover layer 480 that has no porosity, no dryness; no fibre distortion; meets gloss/matte specifications out of mould.

[0173] As described for the second embodiment, the wheel body 350 and fascia layer 400 can include any suitable resin. The wheel body 350 can be formed from a first resin and the fascia layer 400 can be formed from a second resin. Each of the first and second resins is preferably based on unsaturated polyester, polyurethane, polyvinyl ester, epoxy, thermosets, thermoplastics, or combinations thereof.

[0174] Similarly, the fascia layer 400 and moulded resin cover layer 480 is preferably formed from any resin (second resin) having an aesthetically acceptable cured colour. The second resin is preferably selected from at least one of epoxy, polyurethane, polyester, or vinylester. In many embodiments, the second resin infused into the fascia ply layup in step 3 comprises a UV resistant resin. In preferred forms of this third embodiment, the second resin used for the fascia layer 400 and moulded resin cover layer 480 comprises a polyurethane resin, and preferably a clear polyurethane resin. The various advantages of using a polyurethane resin are detailed above, but importantly for this embodiment allow both the fascia layer 400 and moulded resin cover layer 480 to be produced with a final glossy finish, where no further finishing process such a spray painting a clear coating or other coating is required. In this respect, a clear polyurethane resin on the moulded resin cover layer 480 on the inner barrel coating is applied as a protective coating to that surface. An uncoated epoxy can be eroded under weathering conditions. Epoxy therefore needs to be coated using a sprayed-on coating for example a clear coating, or in this case in the moulding process to provide a polyurethane protective coating over the epoxy resin.

[0175] Those skilled in the art will appreciate that the invention described herein is susceptible to variations and modifications other than those specifically described. It is understood that the invention includes all such variations and modifications which fall within the spirit and scope of the present invention.

[0176] Where the terms “comprise”, “comprises”, “comprised” or “comprising” are used in this specification (including the claims) they are to be interpreted as specifying the presence of the stated features, integers, steps or components, but not precluding the presence of one or more other feature, integer, step, component or group thereof.

[0177] Future patent applications may be filed in Australia or overseas on the basis of or claiming priority from the present application. It is to be understood that the following provisional claims are provided by way of example 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 so as to further define or re-define the invention or inventions.