Patent Application
20220305843
This disclosure relates to composite wheels, and more specifically to wheels comprising fiber reinforced thermoset composites.
Fiber-reinforced composite wheels have been recognized for providing performance advantages for road vehicles due to their relatively light weight and reduced rotational inertia. This reduction in rotational inertia and mass (or weight) results in significantly faster acceleration, reduced braking distance, improved handling, the ability to reduce unsprung mass (e.g., the mass of other suspension components such as axles and wheel bearings), and reduced road noise. As a result, fiber-reinforced wheels are widely used in luxury vehicles and sports cars, and are beginning to appear on lower priced vehicles.
Notwithstanding the significant advantages associated with fiber-reinforced composite wheels as compared to steel and metal alloy wheels, there remains a need for structures that provide improved mechanical properties as compared with currently available fiber-reinforced composite wheels.
It has been discovered that improved structural integrity can be achieved in a fiber-reinforced composite wheel by laying fiber plies during wheel fabrication such that at least one of the plies in the completed wheel is continuous from one spoke, through the hub, and through another spoke.
It has also been discovered that improved strength and resistance to wheel damage during high stress cornering or in the event of impact with a curb or pot-hole can be achieved in a fiber-reinforced composite wheel having a barrel and a mount, by laying plies during fabrication such that the plies in the completed wheel extends continuously through at least a portion of a spoke and through at least a portion of the barrel.
Shown in
Wheel 10 is fabricated in a fixture employing known techniques of hand laying or machine laying multiple overlapping plies. The plies are comprised of strong fabric pieces made of fibers that provide reinforcement and strength to the finished wheel. Each ply can consist of one or more fiber tows. A fiber tow is an untwisted bundle of continuous filaments. A tailored fiber placement preform refers to a stitched reinforcing structure made using embroidery machines that precisely stitch fiber roving material onto a base material. The fiber tows and plies can be comprised of glass (e.g., silica-based glass containing metal oxides), boron, aramid, carbon, or other high strength reinforcing fibers. After the layup is completed, the layed-up plies are compressed and sealed in a molding fixture. A thermosetting or thermoplastic resin is injected into the mold, which may be preheated, and the resin is cured or hardened. After the resin has cured (i.e., crosslinked into a bonded state, or solidified in the case of thermoplastic resin), the molded part is demolded, cut and trimmed (e.g., manually or by a robot) to provide a completed wheel 10. Suitable thermosetting resins include unsaturated polyester resins, vinyl ester resins, epoxy resins, phenolic resins, polyurethane resins, and polyamide resins. Examples of thermoplastic resins include polycarbonates, acrylic resins, polyester resins, polyamides and polyurethanes.
The plies (fabric pieces) can be non-woven or randomly oriented fibrous mats, woven fabrics, knitted fabrics, stitched fabrics, tailored fiber placement performs and/or braided fabrics (made by intertwining three or more yarns without any two yarns being twisted around each other).
The plies can be pre-impregnated with a thermosettable or non-thermosettable resin to facilitate assembly.
As shown in
The layed-up plies 20 shown in
Accordingly, it is to be understood that the above description is intended to be illustrative and not restrictive. Many embodiments and applications other than the examples provided would be apparent upon reading the above description. The scope of the invention should be determined with reference to the appended claims along with the full scope of equivalents to which such claims are entitled. It is anticipated and intended that future developments will occur, and that the disclosed systems and methods will be incorporated into such future embodiments. In summary, it should be understood that the invention is capable of modification and variation.
