Carbon Revolution Limited

Carbon Revolution Pty Ltd.

Ashley James Denmead

Matthew Edward Dingle

Michael Dunbar Silcock

Timothy Corbett

Donald Brett Gass

Nicholas Taylor

Barry Trippit

Eden Kwok

Steven Agius

Hugo Howse

Nathan Jones

Aaron Brighton

Stefen Sens

Haydn Law

David Dellios

A shaped preform component (A) for a spoke portion (A) of a composite wheel (), the shaped preform (A) comprising: an elongate body () configured to be located in a spoke () of a composite wheel (), wherein the shaped preform component (A) 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 () to the composite wheel ().

Shaped preform for spoke portion of a composite wheel

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

Composite wheel with improved mounting formation

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 +&#x398; or &#x2212;&#x398; to the circumferential axis of the rim portion, wherein &#x398; is from 26&#xb0; to 40&#xb0;.

Rim fibre architecture of a composite wheel

A shaped preform component () for a face portion () of a composite wheel (), the shaped preform () having a hub () that extends around a central axis (Y), the shaped preform component () being formed from a cured composite fibre material having a compressibility of &#x3c;2% volumetric under moulding conditions of 50 bar hydrostatic pressure and a temperature of 60 to 200&#xb0; C.

Shaped preform for face portion of a composite wheel

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

Method of producing thermally protected composite

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.

Centre-lock attachment arrangement for composite wheels

A connection () between a rim portion () and a face portion () of a composite wheel (). The rim portion () comprises a first set of fibers (). The face portion () comprises a second set of fibers (). The connection () comprises a transition zone () in which the first set of fibers () and the second set of fibers () are arranged in a layered structure. Each layer (A,B,C) of the layer structure includes a first section () including an arrangement of the first set of fibers (), and a first connection end (), and a second section () including an arrangement of the second set of fibers (), and a second connection end (). The first connection end () is arranged adjacent to or abutting the second connection end () forming a layer joint (A,B,C). The layer joint (A,B,C) of each adjoining layer (A,B,C) is spaced apart in a stepped configuration.

Face to rim connection for a composite wheel

A connection between a face portion () and a hub portion () of a composite wheel (). The hub portion () comprises a generally disc shaped hub plate (), and the face portion () comprises a plurality of spokes (). The connection comprises an annular hub ring () surrounding the hub plate (), the hub ring () comprising a plurality of layers of reinforcement fibers extending in an at least generally circumferential direction about the hub ring (). The connection also comprises a first plurality of layers of reinforcing fibers () extending in a generally radial direction R relative to an axis of rotation of the wheel (), and along a front face of each spoke (), across a front edge () and an inner annular surface () of the hub ring () and across a front face () of the hub plate (); and a second plurality of layers of reinforcing fibers () extending in a generally radial direction R along a rear face () of each spoke (), across a rear edge () of the hub ring () and across a rear face () of the hub plate (). The connection further comprises a third plurality of layers of reinforcing fibers (), the third plurality of layers () of reinforcing fibers overlaying the first and second () layers of reinforcing fibers (), the third plurality of layers of reinforcing fibersextending in a direction between +30 degrees and +60 degrees to the radial direction R; and a fourth plurality of layers of reinforcing fibers (), the fourth plurality of layers of reinforcing fibers () overlaying the first and second layers of reinforcing fibers (, (), the fourth plurality of layers of reinforcing fibers () extending in a direction () between &#x2212;30 degrees and &#x2212;60 degrees to the radial direction R.

Face to hub connection for a composite wheel

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. The fastening side includes at least one engagement surface configured to operatively engage a complementary portion of the fastening nut when the fastening nut is assembled on the elongate fastener element. The fastening arrangement also includes a sleeve which extends axially relative to the fastening axis outwardly from the base about the fastening aperture. The sleeve is configured to extend into the attachment aperture of the composite wheel. The sleeve also includes a distal end configured to be received in a complementary shaped sleeve aperture located in the mount or in an element located adjacent the mount.

Growing community of inventors

Belmont, Australia

Ashley James Denmead