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 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 (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 (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 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 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.

Abstract: A connection between a face portion (12) and a hub portion (14) of a composite wheel (10). The hub portion (14) comprises a generally disc shaped hub plate (16), and the face portion (12) comprises a plurality of spokes (18). The connection comprises an annular hub ring (22) surrounding the hub plate (16), the hub ring (22) comprising a plurality of layers of reinforcement fibers extending in an at least generally circumferential direction about the hub ring (22).

Abstract: A centre-lock attachment arrangement attaching a composite wheel to a mount using a centre-lock fastener and a centre-lock fastening nut which can be fastened on the centre-lock fastener. The composite wheel including a central attachment area having a central attachment aperture through which the centre-lock fastener is inserted; a front element including an attachment aperture through which the centre-lock fastener is inserted; a backing element including an attachment aperture through which the centre-lock fastener is inserted; a plurality of fastener apertures annularly spaced around the attachment aperture of the composite wheel, the front element and the backing element; and a plurality of elongate fasteners configured to be received through the aligned apertures of the front element and the backing element which, in use, clamp the front element and the backing element over and around the central attachment area of the composite wheel.

Abstract: The present invention provides an attachment arrangement for use in attaching at least one composite wheel to a mount using an elongate fastener element and a fastening nut which can be fastened on the elongate fastener element. The attachment arrangement is used with a composite wheel that includes at least one attachment aperture through which the elongate fastener element is inserted. The attachment arrangement includes a fastening washer having a fastening aperture through which the elongate fastener element can be inserted when in use. The fastening aperture includes a radially central fastening axis. The fastening washer also has a base configured to face a surface of the composite wheel about the attachment aperture. In addition, the fastening washer has a fastening side facing substantially axially outwardly from the attachment aperture.

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 fibres (122). The face portion (104) comprises a second set of fibres (124). The connection (110) comprises a transition zone (120) in which the first set of fibres (122) and the second set of fibres (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 fibres (122), and a first connection end (128), and a second section (129) including an arrangement of the second set of fibres (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.

Abstract: A connection between a face portion (12) and a hub portion (14) of a composite wheel (10). The hub portion (14) comprises a generally disc shaped hub plate (16), and the face portion (12) comprises a plurality of spokes (18). The connection comprises an annular hub ring (22) surrounding the hub plate (16), the hub ring (22) comprising a plurality of layers of reinforcement fibres extending in an at least generally circumferential direction about the hub ring (22).