Hybrid Composite Wheel

Abstract

A road wheel for a vehicle includes a face portion and a rim portion. The face portion is formed from a metallic alloy and defines a central portion plurality of spokes extending between the central portion and a proximal bead element. The rim portion is formed from a composite material and defines an annular wall circumscribing a wheel axis extending to a distal bead element from said face portion. The proximal bead element is defined by the metallic alloy and the distal bead element is defined by the composite. The face portion and the rim portion are interconnected in interlocking engagement.

1 - 11 . (canceled) 
     
     
         12 . The method set forth in  claim 25 , further including the step of selecting a first material having a substantially same rate of thermal expansion as said second material. 
     
     
         13 . The method set forth in  claim 25 , further including a step of applying adhesive between said face mating element and said rim mating element for adhering said face mating element to said rim mating element. 
     
     
         14 . The method set forth in  claim 25 , wherein said step of forming said face portion from a first material is further defined by forming said face portion from a metal alloy and said step of forming said rim portion is further defined by forming said rim portion from a thermoplastic composite material. 
     
     
         15 . The method set forth in  claim 14 , wherein step of forming said rim portion from a composite material is further defined by encasing reinforcing fibers within said composite material. 
     
     
         16 . The method set forth in  claim 13 , wherein said step of encasing reinforcing fibers within said composite material is further defined by encasing a plurality of different reinforcing fibers in said composite material. 
     
     
         17 . The method set forth in  claim 13 , wherein said step of forming said rim portion from a composite material is further defined by encasing reinforcing fibers having a plurality of different orientations. 
     
     
         18 . The method set forth in  claim 25 , wherein said step of forming a rim portion from a second material is further defined by said second material defining a first density and a second density within said rim portion, with said second density being different than said first density. 
     
     
         19 . The method set forth in  claim 25 , further including the step of forming said rim portion from a plurality of thermoplastic preforms and interconnecting said thermoplastic preforms by heating said thermoplastic preforms. 
     
     
         20 . The method set forth in  claim 25 , further including the step of forming a distal bead element from composite material and proximal bead element from abutting composite material and metallic alloy. 
     
     
         21 . The method set forth in  claim 25 , Wherein said step of affixing said face mating element to said rim mating element is further defined by adhering said face mating element to said rim mating element with an adhesive. 
     
     
         22 . The method set forth in  claim 25 , wherein said step of affixing said face mating element to said rim mating element is further defined by mechanically affixing said face mating element to said rim mating element. 
     
     
         23 . The method set forth in  claim 25 , wherein said step of generating a preform of a rim portion from a second material is further defined by forming said preform from a thermoplastic. 
     
     
         24 . The method set forth in  claim 23 , wherein said step of heating said preform of said rim element is further defined by placing said preform in a die cavity and heating said die cavity to a melting temperature of said second material. 
     
     
         25 . A method of manufacturing a vehicle wheel, comprising the steps of:
 forming a face portion from a first material including a face mating element;   generating a preform of a rim portion from a second material including a rim mating element;   heating said preform of said rim portion thereby modifying a configuration of the preform;   forming said rim portion to a net or near-net shape by cooling said preform to ambient temperature; and   affixing said face mating element to said rim mating element.