Abstract: A shaped preform component (200A) for a spoke portion (108A) of a composite wheel (100), the shaped preform (200A) comprising: an elongate body (215) configured to be located in a spoke (108) of a composite wheel (100), wherein the shaped preform component (200A) is formed from a cured composite fibre material having a compressibility of <2% volumetric under moulding conditions of 50 bar hydrostatic pressure and a temperature of 60 to 150° C., and wherein the density of the cured composite fibre material is selected to form a counterbalance mass for a mass addition (300) to the composite wheel (100).

Abstract: The invention relates to a composite wheel (200) including a hub (202), a rim (204) and a connection structure (206) connecting the hub (202) to the rim (204). The hub (202) has front (208) and rear (209) faces and is formed with one or more mounting formations (216) for, in use, receiving a fastener to mount the hub (202) to a mounting surface of a vehicle. Each mounting formation (216) includes a fastening region (218) recessed into the front face (208) of the hub (202) and includes a fastener aperture (212) defining a passage between the fastening region (218) and the rear face (209) of the hub. Each mounting formation (216) also includes a front-to-fastener ply (224) extending between a front region of the hub and the fastening region (218) for, in use, transferring load between the front region of the hub (202) and the fastening region (218).

Abstract: A rim portion of a composite wheel comprises a shaped annulus formed about a central axis of rotation of the composite wheel and having a circumferential axis extending circumferentially about the central axis and around the rim portion, said rim portion having a fibre layup comprising a stacked laminate formed from alternating layers of: a hoop tow layer comprising elongate fibre tow in which the fibres are substantially aligned with the circumferential axis of the rim portion, the hoop tow layer being formed from at least one annularly wound elongate fibre tow; and a bias ply layer comprising at least one fibre ply in which the fibres are substantially orientated at an angle of +? or ?? to the circumferential axis of the rim portion, wherein ? is from 26° to 40°.

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.

Abstract: A shaped preform component (200) for a face portion (104) of a composite wheel (100), the shaped preform (200) having a hub (206) that extends around a central axis (Y), the shaped preform component (200) being formed from a cured composite fibre material having a compressibility of <2% volumetric under moulding conditions of 50 bar hydrostatic pressure and a temperature of 60 to 200° C.

Abstract: A shaped preform component (200) for a face portion (104) of a composite wheel (100), the shaped preform (200) having a hub (206) that extends around a central axis (Y), the shaped preform component (200) being formed from a cured composite fibre material having a compressibility of <2% volumetric under moulding conditions of 50 bar hydrostatic pressure and a temperature of 60 to 200° C.

Abstract: A rim portion of a composite wheel comprises a shaped annulus formed about a central axis of rotation of the composite wheel and having a circumferential axis extending circumferentially about the central axis and around the rim portion, said rim portion having a fibre layup comprising a stacked laminate formed from alternating layers of: a hoop tow layer comprising elongate fibre tow in which the fibres are substantially aligned with the circumferential axis of the rim portion, the hoop tow layer being formed from at least one annularly wound elongate fibre tow; and a bias ply layer comprising at least one fibre ply in which the fibres are substantially orientated at an angle of +? or ?? to the circumferential axis of the rim portion, wherein ? is from 26° to 40°.

Abstract: A shaped preform component (200A) for a spoke portion (108A) of a composite wheel (100), the shaped preform (200A) comprising: an elongate body (215) configured to be located in a spoke (108) of a composite wheel (100), wherein the shaped preform component (200A) is formed from a cured composite fibre material having a compressibility of <2% volumetric under moulding conditions of 50 bar hydrostatic pressure and a temperature of 60 to 150° C., and wherein the density of the cured composite fibre material is selected to form a counterbalance mass for a mass addition (300) to the composite wheel (100).

Abstract: The invention relates to a composite wheel (200) including a hub (202), a rim (204) and a connection structure (206) connecting the hub (202) to the rim (204). The hub (202) has front (208) and rear (209) faces and is formed with one or more mounting formations (216) for, in use, receiving a fastener to mount the hub (202) to a mounting surface of a vehicle. Each mounting formation (216) includes a fastening region (218) recessed into the front face (208) of the hub (202) and includes a fastener aperture (212) defining a passage between the fastening region (218) and the rear face (209) of the hub. Each mounting formation (216) also includes a front-to-fastener ply (224) extending between a front region of the hub and the fastening region (218) for, in use, transferring load between the front region of the hub (202) and the fastening region (218).

Abstract: A method of producing a composite component (10) having a thermal protection layer (24) including the steps of: providing a composite component (10) with a primary fibre material (12) and with a primer layer (16) of alternative fibre material overlying the primary fibre material (12) at an area of the composite component intended for high thermal exposure, said area defining a thermal exposure area (18); applying a metallic bonding layer (22) to the primer layer (16) of the thermal exposure area (18) to create a bonding surface at the thermal exposure area (18); and applying a ceramic thermal protection layer (24) to the bonding surface for insulating the thermal exposure area (18) and/or for reflecting external thermal energy, the thermal protection layer (24) having a higher melting point than the metallic bonding layer (22).

Abstract: A center-lock attachment arrangement for use in attaching a composite wheel to a mount. TA front element includes an outer engagement surface engaging a center-lock fastening nut and an inner engagement surface engaging an outer side of a central attachment area of the composite wheel. The front element further includes an attachment aperture through which a center-lock fastener is inserted and a plurality of fastener apertures around the attachment. A backing element includes an outer engagement surface facing the mount and an inner engagement surface engaging with an inner side of the central attachment area. The backing element further includes an attachment aperture through which the center-lock fastener is inserted and a plurality of fastener apertures around the attachment aperture. Elongate fasteners received through the aligned apertures of the front and the backing element clamp the front and the backing element over and around the central attachment area.

Abstract: A connection (110) between a rim portion (102) and a face portion (104) of a composite wheel (100). The rim portion (102) comprises a first set of fibers (122). The face portion (104) comprises a second set of fibers (124). The connection (110) comprises a transition zone (120) in which the first set of fibers (122) and the second set of fibers (124) are arranged in a layered structure. Each layer (125A, 125B, 125C) of the layer structure includes a first section (127) including an arrangement of the first set of fibers (122), and a first connection end (128), and a second section (129) including an arrangement of the second set of fibers (124), and a second connection end (130). The first connection end (128) is arranged adjacent to or abutting the second connection end (130) forming a layer joint (132A, 132B, 132C). The layer joint (132A, 32B, 132C) of each adjoining layer (125A, 125B, 125C) is spaced apart in a stepped configuration.