Patent Description:
Passenger vehicle wheels are known in the art, and are typically formed of one or more materials to define the shape of the wheel. The wheel may be sized and shaped such that it is configured to support a tire mounted thereon, and such that the wheel may be mounted to a rotatable axle so the wheel can be driven by a vehicle transmission and rotated in response to the vehicle being driven.

Different portions of the wheel have different strength or temperature requirements based on the different functions performed by the different portions. Accordingly, the wheel may have various thicknesses, fiber angles, and/or carbon fiber materials that are used throughout the different wheel portions or areas.

For example, a typical wheel may include a pair of tire bead flanges, such as an inner bead flange and an outer bead flange. The bead flanges typically must have very high impact performance and toughness to perform well when subjected to a pothole impact. Thus, increasing the toughness at this area is advantageous.

It is also known that in the area of the wheel that interfaces with the vehicle brake calipers, it is desirable to have an elevated temperature performance, such that the wheel material can sufficiently withstand the increased temperatures that result from the friction generated during a braking operation.

In the state of the art is known the document <CIT> which discloses a wheel suitable for a vehicle, comprising a rim, wherein the rim comprises a rim bed, characterised in that the rim bed comprises a wound tape comprising a fibre reinforced thermoplastic or thermoset polymer matrix.

Typical composite wheel manufacturing processes utilize the same resin or material matrix for the entire wheel construction. This process therefore results in a single material being used for each of the areas of the wheel. Wheels may be manufactured using the same resin and varying the radial thickness of the wheel to provide different strengths at different portions of the wheel. Nevertheless, the use of the same matrix material will result in a compromise between strength, temperature performance, and cost.

One solution for the different requirements of the wheel is the use of different resins for different portions of the wheel. In some approaches, different resins can be "co-cured" to produce a wheel with different strength and temperature performance at different locations.

Various approaches may be used to construct a wheel with different resins. In one approach, a first preform is constructed which includes one matrix system, which may be uncured or already cured. A second preform may be constructed using a different matrix system, which may be cured or uncured. The preforms may then be placed in a mold together and then cured together.

In another approach, a preform, such as a fiber preform, may be placed in a Resin Transfer Mold (RTM), where a liquid thermoset resin is used to saturate the fiber preform in a closed mold. The result is that the preform becomes embedded in the thermoset resin. In this approach, a first matrix system may be infused into one region of the preform, and a second matrix system is infused into another region of the preform. The two matrix systems may then be cured together to define an overall composite with the embedded preform.

The above-described methods are typically used for simplifying the bonding of multiple composite parts. The result is typically a difference in thickness along the axial width of the wheel. Put another way, there can be multiple layers of material. In this approach, each layer uses the same matrix, but some of the layers along the thickness of the wheel have different properties.

In the above-described approach, the reinforcement materials are not continuous across the multiple resin regions. Put another way, one reinforcement area with a first resin material will overlap another portion with a reinforcement area with a second resin, such that the first resin overlaps the second resin at an increased thickness area. This method is known as an overlap method, and is illustrated in <FIG>.

In another approach, known as the splice method and shown in <FIG>, a first resin material is formed in layers with different lengths, such that a middle layer may have a longer length, and is received in a recess formed between layers, with the second resin material having a shorter length such that the longer length can be received in a recess defined by the shorter length.

The overlap and/or seam that is created in these prior art solutions is undesirable and can create a part that is overly bulky or lacking in a desirable strength.

In view of the above, improvements can be made to the construction of composite vehicle wheels.

It is an aspect of this disclosure to provide a composite wheel structure with different strength and temperature characteristics in different axial portions of the wheel.

It is another aspect of this disclosure to provide a composite wheel structure with a continuous reinforcement layer.

It is a further aspect of this disclosure to provide a composite wheel structure with a reduced cost.

In accordance with the above and the other aspects of the disclosure, in one aspect, a composite wheel structure is provided including a wheel body having an axial width extending between an inner end and an outer end. The wheel structure includes an inner flange portion of the wheel body disposed at the inner end and an outer flange portion of the wheel body disposed at the outer end.

A first intermediate portion of the wheel body is disposed between the inner flange portion and the outer flange portion. A second intermediate portion of the wheel body is disposed between the first intermediate portion and the outer flange portion.

A first reinforcement layer of material extends between the inner and outer ends and extends through the inner flange portion, the outer flange portion, the first intermediate portion, and the second intermediate portion. The first reinforcement layer is in the form of a single continuous fiber layer.

A first matrix material is integrated with the first reinforcement layer along the inner flange portion. A second matrix material is integrated with the first reinforcement layer along the first intermediate portion. A third matrix material is integrated with the first reinforcement layer along the second intermediate portion.

In one aspect, the outer flange portion and inner flange portion each include the first matrix material.

In one aspect, the first matrix material has high toughness and low temperature performance.

In one aspect, the second matrix material has high temperature performance and low toughness.

In one aspect, the third matrix material has low temperature performance and low toughness.

In one aspect, the second matrix material comprises a Bismaleimide polymer and the first and third matrix materials are epoxy.

In one aspect, the first reinforcement layer is a carbon fiber fibric, Kevlar, or fiberglass.

In one aspect, the first reinforcement layer is seamless across the axial width of the wheel body.

In one aspect, the first, second, and third matrix materials are joined with the first reinforcement layer in a single layer, such that the single reinforcement layer includes different matrix materials across its width.

In one aspect, the composite wheel structure further includes at least one additional reinforcement layer overlaying the first reinforcement layer, wherein the at least one additional reinforcement layer is continuous and seamless and includes multiple different integrated matrix materials across an axial width thereof.

In another aspect, a method of forming a composite layer for use in a composite wheel layup process is provided. The method includes the steps of providing a single reinforcement layer in the form of a continuous fabric material having a lateral width. The method further includes applying a first matrix material onto a first portion of the reinforcement layer and applying a second matrix material onto a second portion of the reinforcement layer. The method also includes consolidating the first and second matrix materials and the reinforcement layer into a single composite layer.

In one aspect, the step of consolidating includes prepregging the reinforcement layer with the first and second matrix materials.

In one aspect, the step of consolidating includes applying pressure and heat to the reinforcement layer and the first and second matrix materials.

In one aspect, the step of consolidating includes using a resin film infusion process.

In one aspect, the method further includes providing a substrate having a length and a width; applying the first matrix material to the substrate across a first portion of the width; applying the second matrix material to the substrate across a second portion of the width; defining a single resin film that includes the first and second matrix materials applied to the substrate; wherein the steps of applying the first and second matrix materials includes overlaying the single resin film on the reinforcement layer.

In one aspect, the method further includes providing a first substrate having a length and a width; applying the first matrix material to the first substrate across the width thereof; providing a second substrate having a length and a width; applying the second matrix material to the second substrate across the width thereof; defining a first resin film that includes the first matrix material applied to the first substrate; defining a second resin film that includes the second matrix material and the second substrate; wherein the steps of applying the first and second matrix materials includes overlaying the first resin film and the second resin film onto the reinforcement layer.

In one aspect, the first matrix material and the second material are applied to the reinforcement layer side-by-side during a first time period.

In one aspect, the first matrix material and the second matrix material are applied to the reinforcement layer side-by-side, with the first matrix material applied during a first time period and the second matrix material applied during a second time period.

In one aspect, the single composite layer is formed with the single reinforcement layer impregnated with first and second matrix materials across the width of the reinforcement layer, wherein the first and second matrix materials do not overlap across the width of the reinforcement layer, and the reinforcement layer is seamless.

In one aspect, the first and second matrix materials are applied to the reinforcement layer using a direct reinforcement coating process in which the first and second matrix materials are directly applied to the reinforcement layer without previously applying the matrix materials to a substrate.

In yet another aspect, a composite wheel structure is provided that includes a wheel body having an axial width extending between an inner end and an outer end. The wheel structure includes a first axial portion of the wheel body, and a second axial portion of the wheel body.

The structure further includes a fabric reinforcement layer in the form of a single axially continuous layer extending through the first and second axial portions. The reinforcement layer is impregnated with a first matrix material along the first axial portion and a second matrix material along the second axial portion.

Other aspects of the present disclosure will be readily appreciated, as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings wherein:.

Referring to <FIG>, a vehicle wheel <NUM> construction is provided having multiple matrix materials across the axial width of the wheel <NUM>. The wheel <NUM> may include a wheel body <NUM> having multiple axial zones, areas, or portions 12a, b, c, d, etc. The body portions may be referred to generally using the reference numeral <NUM>, with specific zones being referred to as 12a, b, c, d, etc..

The zones <NUM> may be formed as a continuous fiber layer having different resin materials used in the different zones <NUM>. As shown in <FIG>, a first zone 12a may be disposed at and may define an axially inner end portion of the wheel <NUM>, and may further define an inner bead <NUM>. A second zone 12b may extend generally axially outwardly away from the first zone 12a, and may define a generally cylindrical portion <NUM>. A third zone 12c may extend generally axially outwardly from the second zone 12b, and may define a curved or tapered cross-section with a diameter that reduces relative to the second zone 12b along the axial width of the wheel <NUM>, which may be described as a curved portion <NUM> or stepped portion. A fourth zone 12d may extend generally axially outwardly from the third zone 12c, and may have a diameter that increases relative to the third zone 12c. The fourth zone 12d may define an outer bead <NUM>. it will be appreciated that the reference to extending generally axially outwardly refers to the general direction away from the inner bead <NUM>, and may include tapering or other complex diameter changes, and should not necessarily be interpreted as extending parallel to the rotational axis of the wheel due to the possible tapering and diameter changes.

It will be appreciated that the illustrated arrangement and number of zones <NUM> may be modified in accordance with design needs. As further described below, the illustrated zones 12a-12d may be tailored to accommodate a particular use environment, such as for temperature resistance or strength at different areas. Of course, given the various temperature and strength needs for different designs, additional zones may be included, or the relative sizes of the illustrated zones 12a-12d may be modified. For purposes of further discussion, the number and arrangement of zones 12a-12d will be referenced herein.

The inner bead <NUM> and the outer bead <NUM> may be sized and configured to support a tire (not shown) in a traditional manner, such that the tire may be inflated when mounted and sealed to the wheel <NUM> in a manner known in the art.

The zones <NUM> may combine to define an outer surface <NUM> and an inner surface <NUM>. The outer surface <NUM> faces radially outward and combines with a mounted tire to define an interior space within the tire in which pressurized air may be introduced to inflate the tire. The inner surface <NUM> faces radially inward and toward the axis of the rotation of the wheel. The inner surface <NUM> may be the surface that interfaces with a vehicle braking mechanism or is disposed near or adjacent a braking mechanism (not shown). The braking mechanism, as is known, will generate a substantial amount of heat during operation. In one approach, the third zone 12c that defines the curved portion <NUM> is the area of the wheel <NUM> that may interface or be disposed adjacent or near the brake mechanism, and may therefore be the portion of the wheel <NUM> that receives a large amount of heat from the braking mechanism.

However, it will be appreciated that other zones of the wheel <NUM> may be subjected to increased temperature due to braking mechanisms, or the like. Accordingly, it will be appreciated that the zone 12c may extend further axial distances to include these areas of increased temperatures. In another aspect, the zone 12b illustrated in <FIG> may be the zone that is subjected to increased temperature. For the purposes of discussion, the illustrated zone 12c is the zone subjected to increased temperature.

The inner bead <NUM> and the outer bead <NUM> have larger outer diameters relative to the cylindrical portion <NUM> and the curved portion <NUM>, and are the portions that directly support the tire that is mounted to the wheel <NUM>. Accordingly, the inner bead <NUM> and the outer bead <NUM> are the portions of the wheel <NUM> that receive the majority of an impact load, for instance when impacting a pothole or other road imperfection or bump. The inner bead <NUM> and outer bead <NUM> are therefore preferably constructed with high strength and toughness to resist such loads and to prevent or otherwise limit damage in the wheel <NUM> that could lead to depressurization of the tires and require replacement.

Unlike areas of the wheel <NUM> disposed near braking mechanisms, the inner bead <NUM> and the outer bead <NUM> of the wheel <NUM> do not typically undergo significant temperature increases during operation. Accordingly, the first zone 12a and the fourth zone 12d may be constructed with a high toughness material but without requiring high temperature performance. Put another way, these zones defining the inner bead <NUM> and outer bead <NUM> may have high toughness performance but low temperature performance. In one approach, the resin used for these zones may be an epoxy resin material but it is understood this may be any polymeric or non-polymeric material. As used herein, the various materials that can be used in the various zones may also be referred to as matrix materials.

The third zone 12c may be the zone that receives a large amount of heat because of its proximity to the brake caliper. In operation, this region of the wheel <NUM> may undergo temperatures as much as <NUM> degrees F above the other zones of the wheel <NUM>. In one approach, a polymer from a different polymer family relative to the first and fourth zones 12a and 12d may be used. For example, a polymer from the Bismaleimide family may be used in the third zone 12c, while the other zones use an epoxy. In general, the matrix material used in this zone 12c may have a higher temperature performance and consequently a lower toughness than the matrix materials used in zones 12a and 12d. The third zone 12c is disposed radially inward relative to the inner bead <NUM> and the outer bead <NUM>, and therefore does not undergo substantial impact forces from potholes and the like. Accordingly, the third zone 12c may have a relative low toughness performance.

As used herein, reference to low, high, or the like in toughness performance or temperature performance is intended to refer to performance levels relative to other portions of the wheel <NUM>. For example, the zone 12c having a relative low toughness performance may be understood to mean a lower toughness performance relative to the zones 12a and 12d. Similarly, the zones 12a and 12d having a relative high toughness performance may be understood to mean a higher toughness performance than the zone 12c.

The second zone 12b, which is disposed axially between the first zone 12a (requiring high toughness but allowing low temperature performance) and the third zone 12c (requiring high temperature performance but allowing low toughness), may be constructed to have both low toughness and low temperature performance. The second zone 12b may have this low toughness and low temperature performance because this zone does not receive substantial impact loads because it is radially recessed relative to the inner bead <NUM> and the outer bead <NUM>, and further because it does not undergo substantially high temperatures like the third zone 12c. Thus, the second zone 12b may be constructed using low cost materials because it does not require these levels of high performance. In this aspect, the second zone 12b having low toughness and temperature performance may be understood to mean a lower toughness performance relative to the zones 12a and 12d and a lower temperature performance relative to zone 12c.

Moreover, it will be understood that different zones both being described as having low toughness performance may have differing levels of toughness performance relative to each other. For example, with both the zones 12b and 12c having low toughness performance relative to the zones 12a and 12d, one of the zones 12b or 12c may have a lower toughness performance than the other of zone 12b or 12c.

For the purposes of illustration regarding temperature and strength performance, the following exemplary performance values may be used herein.

Low temperature performance may have a Tg between 80C and 120C. High temperature performance may have a Tg above 180C. Tg refers to the glass-liquid transition, or glass transition, value. Glass-liquid transition, or glass transition, is the gradual and reversible transition in amorphous materials (or in amorphous regions with semicrystalline materials) from a hard and relatively brittle "glassy" state into a viscous or rubbery state as temperature is increased. The glass-transition temperature Tg of a material characterizes the range of temperatures over which this glass transition occurs. The Tg value is lower than the melting temperature of the crystalline state of the material, if one exists.

High toughness performance may refer to a fracture toughness of <NUM> J/m^<NUM> to <NUM> J/m^<NUM>. Low toughness performance may refer to a fracture toughness of less than <NUM> J/m^<NUM>.

With reference to <FIG>, the multiple zones of the wheel body <NUM> may be constructed in a continuous manner, unlike the prior art solutions of overlapping or splicing of reinforcements utilizing different matrix systems and separate fiber reinforcement. Rather, the multiple zones of the body <NUM> of the wheel <NUM> may have a continuous single fiber reinforcement layer <NUM>, but with multiple different matrix or resin materials across the axial width of the reinforcement layer <NUM>. For example, the single layer <NUM> may act as the base, skeleton, body, or the like to which the various resin formulations and/or matrix materials are incorporated in the reinforcement layer <NUM>, which may be in the form of a preform. Incorporating the resin formulations into the preform is performed at the reinforcement level. Alternatively, the incorporation of the resin formulations can be performed at the component level or laminate level.

The reinforcement layer <NUM> may be made from a carbon-fiber fabric, fiberglass, Kevlar, or similar material suitable for acting as a continuous reinforcement layer. The resin materials or formulations that are carried on the reinforcement layer <NUM> can be joined with the reinforcement layer <NUM> in different ways. For purposes of discussion, the combined resin materials may be referred to as a resin layer <NUM>.

In one approach, the resin or matrix materials, in the form of films or layers, can be fully consolidated with the reinforcement layer <NUM> before the wheel layup process. When the resin or matrix materials are consolidated with the reinforcement layer <NUM>, this may be referred to as the reinforcement layer <NUM> being impregnated. When the matrix materials and reinforcement layer <NUM> are consolidated and impregnated prior to the wheel layup process, this approach may be referred to as "prepregged," where a consolidated preform is defined that can be applied to a mold during the layup process.

In another approach, one or more resin films or layers <NUM> may be defined, having one or more matrix materials carried on a substrate, and can be applied to the mold along with the reinforcement layer <NUM> during the wheel layup process. The reinforcement layer <NUM> and the resin film can be then be consolidated on the mold in a resin film infusion molding process, also known as "RFI. " In this approach, the layers are not "prepregged" because the impregnating occurs on the mold in response to the RFI process. In another approach, a portion of the resin layer <NUM> is devoid of resin film, leaving a portion of the reinforcement layer <NUM> uncovered by the resin film layer <NUM>. The consolidated reinforcement and resin film layer <NUM> can be prepregged or utilize the RFI process. During consolidation and cure, the portion of the reinforcement layer <NUM> devoid of resin can be infused with resin from the adjacent material zones. Alternatively, this portion of the reinforcement layer <NUM> can be infused with a resin supplied via resin transfer molding or other infusion process during the molding and curing process.

In either the prepregged process or the RFI process, the matrix materials and the reinforcement layer <NUM> become consolidated in the consolidated layer <NUM> in response to the application of heat and pressure.

The various resin materials that may be used for the different zones 12a-12d across the width of the reinforcement layer <NUM> can be applied as separate films or layers <NUM> for each material, or as one film or layer <NUM> with regions of differing resin material. Separate films <NUM> may be combined with the single reinforcement layer <NUM> in the prepregged approach or the RFI approach. Similarly, a single layer <NUM> of multiple resins may be combined with the reinforcement layer <NUM> in the prepregged approach or the RFI approach. The selection of the prepregged approach vs. the RFI approach can depend on the particular manufacturing capabilities or needs of the user. For example, prepregged layers may require specific handling or storage requirements, and the RFI process may require a specific type of molding equipment.

In the prepregged approach, the resin layer <NUM> and the reinforcement layer <NUM> are heated and partially or completely consolidated together to define the single composite layer <NUM>, which includes both the reinforcement layer <NUM> and the resin layer <NUM>, as shown in <FIG>. The fabric-like structure of the reinforcement layer <NUM> is embedded within the resin layer <NUM> when the single composite layer <NUM> is formed. Multiple composite layers <NUM> may be prepregged, which may then be applied on a mold for performing the wheel layup process.

In the RFI approach, the resin layer <NUM> and reinforcement layer <NUM> may be separately placed on the wheel mold, and the RFI process is performed that will consolidate and bond the resin layer <NUM> to the reinforcement layer <NUM> under heat and pressure, which will impregnate the resin layer <NUM> with the reinforcement layer <NUM> on the mold, creating a molded composite layer <NUM> in the shape of the mold. <FIG> also illustrates the resulting composite layer <NUM> of the RFI approach having both the reinforcement layer <NUM> and the resin layer <NUM> in a single layer.

In each of the above processes, the resin layer <NUM> is provided and produced before being applied to the reinforcement layer <NUM>. As described above, multiple resin materials are used across the width of the reinforcement layer <NUM>. In the above-described example, there are four zones of the wheel <NUM> having different toughness or heat requirements and can therefore be four different materials that meet the particular requirements of each zone or region. The resin layer <NUM> can therefore be provided having multiple materials across its width. The resin layer <NUM> may include a substrate that may be used to receive the matrix materials, which can later be peeled away.

The resin layer <NUM> can be in the form of multiple separate layers 42a, 42b, etc. (<FIG>), or the resin layer can be in the form of a single layer with multiple resin portions 44a, 44b, 44c, etc. (<FIG>). It will be appreciated that <FIG> may illustrate either a single layer with multiple resin portions or multiple layers laid side-by-side. <FIG> shows an example of multiple separate layers. In each of these cases, the resin layer(s) <NUM> may be produced prior to being applied to the reinforcement material <NUM>. In the case of separate layers, the resin layer <NUM> may become a single layer after the separate layers have been consolidated with the reinforcement layer <NUM>. In each of these cases, the resin or matrix material forming the layers or portions may be applied to a substrate <NUM>.

The substrate <NUM> may be a layer of material on which the resin or matrix materials can be applied, such that the resin layer <NUM> may be produced and carried on the substrate <NUM> for later application to the reinforcement layer <NUM>. The substrate <NUM> may be a paper, polymeric, or other material suitable to act a substrate for a resin material.

In one approach, which may be referred to as the multiple film approach and shown in <FIG>, the multiple separate resin layers 42a, b, etc. each having a different resin material are produced separately and on separate substrates <NUM>. It will be appreciated that different substrate materials could be used for the separate layers. It will be further appreciated that the same resin materials could be used in separate layers 42a, b, etc. and laid adjacent each other or separated by a layer of a different resin material, depending on the desired performance of the resin material along the width of the reinforcement layer <NUM>. For example, a first resin material may be used for layer 42a, a second resin material may be used for layer 42b, and the first resin material may be used for layer 42c. Or the first material may be used for both zone 42a and 42b, and a second material may be used for zone 42c. The use of different separate layers <NUM> thereby allows for a modular assembly of resin materials across the width of the reinforcement layer.

The resin films or layers <NUM> can be produced using various filming processes. For example, the layers 42a, b, etc. may be produced by gravure coating, reverse roll coating, knife-over-roll coating, metering rod coating, slot die coating, curtain coating, all knife coating, spray coating, powder coating, or any other known coating technique. The filming processes, when complete, may therefore produce the multiple separate resin layers 42a, b, etc. It will be appreciated that different layers could be made by different coating processes.

With the multiple layers <NUM> being produced, they may then be applied to the reinforcement layer <NUM> for the laminating process. The reinforcement layer <NUM> and the resin layers <NUM> may be in the form of a roll of material. The reinforcement layer <NUM> may be provided, with the separate layers <NUM> being applied over a surface of the reinforcement layer <NUM>.

In one approach, one of the layers <NUM> may be applied to the reinforcement layer <NUM> first, thereby covering a portion of the width of the reinforcement layer <NUM>. The reinforcement layer <NUM> and the resin layer <NUM> may then be laminated together, providing a portion of the reinforcement layer <NUM> in a laminated state. Subsequent resin layers <NUM> may be applied and laminated in a similar and sequential manner, until the entire width of the reinforcement layer <NUM> has been covered (or the entire desired amount of the reinforcement layer <NUM> has been covered). With the multiple matrix materials applied to the reinforcement layer <NUM>, heat and pressure may be applied to consolidate the layers according to the prepregged approach or the RFI approach.

In the RFI approach, the reinforcement layer <NUM> may be placed on the wheel mold separately from the matrix material layers <NUM>, or the layers may be laminated together and then applied to the mold. In either version of the RFI approach, the layers <NUM> will be consolidated on the mold to arrive at the consolidated layer <NUM> illustrated in <FIG>.

In another approach, each of the layers <NUM> may be applied to the reinforcement layer <NUM> side-by-side generally simultaneously or during the same time period. In this approach, the rolls of the layers <NUM> may be located side by side and the lamination may occur at the same distance along the reinforcement layer <NUM>. Put another way, at a given longitudinal location along the reinforcement layer <NUM>, the multiple layers <NUM> may be applied across the width at the same longitudinal location.

This approach of applying multiple separate layers <NUM> to the reinforcement layer <NUM> can thereby provide a laminated and prepregged composite layer <NUM> that may be applied to the wheel mold in the wheel layup process, or a laminated assembly of layers that can be consolidated in the RFI approach. In the prepregged approach, heat and pressure are applied to the overlaid reinforcement layer <NUM> and layers <NUM>, and the consolidated layer <NUM> is placed on or in the wheel mold. In the RFI approach, the overlaid layers <NUM> and <NUM> are placed on or in the mold prior to applying heat and pressure to create the consolidated layer <NUM>.

With reference to <FIG>, in another aspect, the resin layer <NUM>, in the form of a single layer with multiple portions 44a, b, c, etc., can be produced and subsequently laminated with the reinforcement layer <NUM>. In this approach, the resin layer <NUM> may be produced using a filming process in which multiple resin formulations are applied to the substrate <NUM> at approximately the same time. An example of such a filming process is shown in <FIG>, in which a filming setup <NUM> for a knife-over-roll process is illustrated.

In this approach, the substrate <NUM> may be fed in a first direction toward a lower roller 60a, and directed upward toward an upper roller 60b. At the upper roller 60b, the substrate <NUM> is directed in a second direction that is opposite the first direction. The substrate <NUM> may be fed in the second direction toward a doctor blade head <NUM> having multiple sections <NUM> with damming <NUM> disposed between the sections <NUM>. Each section <NUM> may include a different resin formulation. Thus, as the substrate <NUM> passes through the sections <NUM>, the different resin formulations may be applied to the substrate <NUM>.

It will be appreciated that in some aspects, the substrate may be fed toward the doctor blade head <NUM> in another manner, and not necessarily using the two-roller setup illustrated in <FIG>.

As the substrate <NUM> passes through the sections <NUM> and the doctor blade head <NUM>, the resin layer <NUM> will be formed having different resin material formulations disposed across the width of the substrate <NUM>, yielding a single resin layer <NUM> with multiple zones. The resin layer <NUM> may then be removed from the setup <NUM>.

With the resin layer <NUM> produced using this process, the resin layer <NUM> is in the form of a single layer, and may then be combined with the reinforcement layer <NUM> to create the composite layer <NUM> in a manner similar to that described above for multiple layers. The single resin layer <NUM> may be applied to the reinforcement layer <NUM>, and heat and pressure may be applied to the resin layer <NUM> and the reinforcement layer <NUM> to form the prepregged composite layer <NUM>. The composite layer <NUM> may then be applied to the mold in the wheel layup process. Alternatively, the single resin layer <NUM> may be applied to the reinforcement layer, and consolidated as part of an RFI process in the mold.

It will be appreciated that the single layer <NUM> having multiple different resin zones may also be combined with additional separate layers and overlaid with the reinforcement layer <NUM> in a manner similar to that described above for multiple layers <NUM>.

In yet another approach, similar to the above-described approach for forming the single resin layer <NUM>, the substrate material <NUM> may be fed through multiple filming stations to apply to the multiple resin formulations to the single substrate <NUM>, rather than a single filming station where the resin formulation are added at approximately the same longitudinal location. For example, the substrate <NUM> may be passed through a first filming station, and the resin material may be applied across a portion of the width of the substrate <NUM>. The substrate <NUM> may continue to be advanced to a subsequent filming station, where another resin material may be applied across a different portion of the width of the substrate <NUM>. This process may be continued until the desired width of the substrate <NUM> is covered with the desired resin materials.

In yet another approach, one resin material may be applied to a portion of the substrate <NUM> at a first filming station, and then multiple resin materials may be applied at a subsequent filming station. For example, a first resin formulation may be applied at a first filming station, and then second and third resin formulations may be applied at the same filming station, with regions separated by damming or the like.

Similar to the above, once all of the desired resin materials have been applied to the substrate <NUM>, the single resin layer <NUM> may be removed and then applied to the reinforcement layer <NUM>, and they can then be combined under heat and pressure to define a prepregged composite layer <NUM>. The composite layer <NUM> may then be applied to the wheel mold in the wheel layup process. Attentively, the single resin layer <NUM> and the reinforcement layer <NUM> may be consolidated on the mold using an RFI process.

The above-described methods have related to create a prepregged composite layer <NUM> that is subsequently applied to the wheel mold or creating an assembly of layers for an RFI process that creates a consolidated layer <NUM> in the mold. In both cases, a resin layer <NUM> is produced and then combined with a single reinforcement layer <NUM> under pressure and heat to consolidate the layers. However, the resin material may be applied in other ways, as well.

In one aspect, a direct reinforcement coating process may be used to apply the different resin or matrix materials to the single reinforcement layer <NUM>. In this approach, the substrate material and the separate resin layer may not be used in the manner described above. Instead, the resin material may be applied directly to the reinforcement layer <NUM>. The reinforcement layer <NUM> may be optionally placed over a backing material, such as a substrate, table, roller, or the like, to limit the resin coating from seeping through the reinforcement layer <NUM>.

Upon coating the reinforcement layer with the resin material directly, the reinforcement layer <NUM> will include the various resin or matrix materials, and may be placed under heat and pressure to produce the composite layer <NUM>. The composite layer <NUM> may then be applied to the wheel mold for use in the wheel layup process.

In each of the above methods, the resulting single composite layer <NUM> includes a continuous fiber reinforcement extending across the width of the composite layer <NUM>. This continuous reinforcement will thereby extend continuously across the width of the wheel <NUM> that is produced, such that there is no seam or break in the reinforcement layer <NUM>, or an overlap of matrix materials and reinforcing layers. Accordingly, the different portions of the wheel <NUM> having different temperature or strength requirements can be accommodated with the desired resin formulation in each region that can suit the specific requirements. In this manner, it is not necessary to compromise on the toughness and heat requirements to find a suitable resin that could be applied to all zones. The ability to select a particular resin for the requirement of a particular zone allows for increased toughness capability, increased temperature capability, and reduced cost.

Claim 1:
A composite wheel (<NUM>) structure comprising:
a wheel body (<NUM>) having an axial width extending between an inner end and an outer end;
an inner flange portion of the wheel body (<NUM>) disposed at the inner end;
an outer flange portion of the wheel body (<NUM>) disposed at the outer end;
a first intermediate portion of the wheel body (<NUM>) disposed between the inner flange portion and the outer flange portion;
a second intermediate portion of the wheel body (<NUM>) disposed between the first intermediate portion and the outer flange portion;
a first reinforcement layer of material extending between the inner and outer ends and extending through the inner flange portion, the outer flange portion, the first intermediate portion, and the second intermediate portion;
wherein the first reinforcement layer is in the form of a single continuous fiber layer (<NUM>);
a first matrix material integrated with the first reinforcement layer along the inner flange portion;
a second matrix material integrated with the first reinforcement layer along the first intermediate portion; and
a third matrix material integrated with the first reinforcement layer along the second intermediate portion, characterized in that the first matrix material, the second matrix material and the third matrix material are different.