Rim for a Wheel

Abstract

A non-metallic rim for a wheel which may be used for motorised vehicles. The rim has a barrel, a first flange, a second flange, a first bead seat, a second beat seat and a primary structural component. The primary structural component extends into at least the first flange and the barrel, and the primary structural component is capable of bearing the majority of the radial and/or lateral load that is borne by the rim during usage. Additionally, the rim has at least a portion of the first bead seat spaced apart from the primary structural component and/or has a protective insert in between the outer face of the first flange and the primary structural component.

We claim: 
     
         1 . A non-metallic rim for a wheel suitable for a motorised 4-wheeled vehicle or a motorised 2-wheeled vehicle, the rim comprising:
 a barrel;   a first flange and a second flange, each extending radially outward from opposing edges of the barrel;   a first bead seat and a second bead seat, each arranged axially inwardly, respectively, of the first and second flanges;   a primary structural component configured to extend through at least the first flange and the barrel, and being capable of bearing a majority of at least one load borne by the rim during normal usage selected from the group consisting of: radial load, lateral load, and combinations thereof, wherein the primary structural component and the bead seats are bound by a polymer matrix; and   at least one of:   (i) a protective insert configured to be disposed between an axial outer face of the first flange and the primary structural component, the protective insert comprising a non-carbon-fibre material that acts to absorb and/or deflect and/or dissipate energy from a load or impact applied axially and/or radially to the rim; and   (ii) at least a portion of the first bead seat is spaced apart from the primary structural component,   wherein the rim comprises an outer layer also bound by the polymer matrix, wherein the outer layer forms at least part of at least one of: the bead seat and a covering on the protective insert.   
     
     
         2 . The non-metallic rim according to  claim 1 , wherein the primary structural component comprises a substantially vertical section extending a direction substantially perpendicular to an axial direction defined by the barrel, and above the substantially vertical section is a section that curves outwardly toward a top outward edge of the first flange and below the substantially vertical section is a section that curves underneath the bead seat toward the section of the primary structural component that extends into the barrel. 
     
     
         3 . The non-metallic rim according to  claim 2 , wherein the protective insert is disposed between the outer face of the first flange and the substantially vertical section of the primary structural component. 
     
     
         4 . The non-metallic rim according to  claim 1 , wherein the primary structural component further comprises structural fibres and wherein at least some of the structural fibres extend through the primary structural component in a direction parallel to an axial direction with respect to the barrel, when the primary structural component is viewed from a radial direction with respect to the barrel. 
     
     
         5 . The non-metallic rim according to  claim 4 , wherein the structural fibres are selected from the group consisting of: carbon fibres, aramid fibre, glass fibres, and combinations thereof, and wherein the structural fibres have been bound into a fabric. 
     
     
         6 . The non-metallic rim according to  claim 5 , wherein the structural fibres are at least one of: biaxially woven and tri-axially woven. 
     
     
         7 . The non-metallic rim according to  claim 1 , wherein the outer layer forms at least part of the bead seat, a non-carbon fibre filler material is disposed between the first bead seat and at least part of the primary structural component and wherein the filler material acts to absorb and/or deflect and/or dissipate energy from a load or impact applied axially and/or radially to the rim. 
     
     
         8 . The non-metallic rim according to  claim 1 , wherein the outer layer and the primary structural component each comprise a plurality of fabric layers comprising structural fibres, the primary structural component comprising a greater number of fabric layers than the outer layer. 
     
     
         9 . The non-metallic rim according to  claim 8 , wherein at least some of the structural fibres of the primary structural component extend through the primary structural component in a direction parallel to an axial direction, when the primary structural component is viewed from a radial direction, and wherein the outer layer substantially lacks fibres that extend in a direction parallel to an axial direction, when the outer layer is viewed from a radial direction. 
     
     
         10 . The non-metallic rim according to  claim 1 , wherein the primary structural component comprises a triaxial fabric and the outer layer comprises a biaxial fabric. 
     
     
         11 . The non-metallic rim according to  claim 1 , wherein the outer layer extends over an entire side of the barrel closest to the axis of the rim, over the protective insert of the first flange, and, if present, a protective insert of the second flange, over a top outward edge of both of the first and second flanges and axially inward from each of the flanges to form the first and second bead seats, respectively. 
     
     
         12 . The non-metallic rim according to  claim 1 , wherein the protective insert comprises an insert selected from at least one of: a foam, a honeycomb and a plurality of layers arranged axially with respect to one another in which the layers have different stiffnesses with respect to the other plurality of layers. 
     
     
         13 . The non-metallic rim according to  claim 7 , wherein the outer layer overlies the protective insert, the outer layer having a different color with respect to at least one of: the protective insert and any materials that may be disposed between the outer layer and the protective insert, wherein the different color is provided to exhibit a visual indication of damage to the outer layer. 
     
     
         14 . The non-metallic rim according to  claim 1 , wherein a filler material is disposed between the first bead seat and the primary structural component and the filler material is selected from a foam, a honeycomb and a laminate. 
     
     
         15 . The non-metallic rim according to  claim 1 , wherein a filling component is disposed adjacent an end of the primary structural component in the first flange, the filling component running at least part way around the circumference of the rim in the first flange. 
     
     
         16 . The non-metallic rim according to  claim 15 , wherein the filling component comprises substantially unidirectional fibrous material extending in a circumferential direction around the rim. 
     
     
         17 . A wheel suitable for a motorised 4-wheeled vehicle or a motorised 2-wheeled vehicle comprising:
 center member; and   a rim, the rim comprising:   a barrel;   a first flange and a second flange, each extending radially outward from opposing edges of the barrel;   a first bead seat and a second bead seat, each arranged axially inwardly, respectively, of the first and second flanges;   a primary structural component configured to extend through at least the first flange and the barrel, and being capable of bearing a majority of at least one load borne by the rim during normal usage selected from the group consisting of: radial load, lateral load, and combinations thereof; and   at least one of:   (i) a protective insert configured to be disposed between an axial outer face of the first flange and the primary structural component, the protective insert comprising a non-carbon-fibre material that acts to absorb and/or deflect and/or dissipate energy from a load or impact applied axially and/or radially to the rimand:   (ii) at least a portion of the first bead seat is spaced apart from the primary structural component; and   the primary structural component and the bead seats are bound by a polymer matrix,   wherein the rim comprises an outer layer also bound by the polymer matrix, wherein the outer layer forms at least part of at least one of: the bead seat and a covering on the protective insert.   
     
     
         18 . A wheel according to  claim 17 , wherein the wheel is configured for use on a four-wheeled vehicle and the first flange is an outboard flange of the wheel. 
     
     
         19 . A wheel according to  claim 17 , wherein the wheel is configured for use a motorbike. 
     
     
         20 . A method for making a non-metallic rim for a wheel suitable for a motorised 4-wheeled vehicle or a motorised 2-wheeled vehicle, the method comprising: assembling a primary structural component with a first bead seat, a second bead seat and, optionally, a protective insert; and
 binding the primary structural component, bead seats and, if present, a protective insert together in a polymer matrix to form a rim comprising a barrel, a first flange and a second flange, each flange extending radially outward from opposing edges of the barrel, wherein the first bead seat and the second bead seat are each arranged axially inwardly, respectively, of the first and second flanges;   wherein the primary structural component extends through at least the first flange and the barrel, and being capable of bearing a majority of at least one load borne by the rim during normal usage selected from the group consisting of: radial load, lateral load, and combinations thereof; and at least one of:
 (i) the protective insert is disposed between an axial outer face of the first flange and the primary structural component, the protective insert comprising a non-carbon-fibre material that acts to absorb and/or deflect and/or dissipate energy from a load or impact applied axially and/or radially to the rim; and 
 (ii) at least a portion of the first bead seat is spaced apart from the primary structural component, 
   wherein the rim comprises an outer layer also bound by the polymer matrix, wherein the outer layer forms at least part of at least one of: the bead seat and a covering on the protective insert.