Carbon Revolution Limited

Carbon Revolution Pty Ltd.

Michael Dunbar Silcock

Ashley James Denmead

Matthew Edward Dingle

Timothy Corbett

Nicholas Taylor

Donald Brett Gass

Barry Trippit

Steven Agius

Eden Kwok

Nathan Jones

Hugo Howse

Stefen Sens

Aaron Brighton

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 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 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.

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Caulfield North, Australia

Michael Dunbar Silcock