Patent US4294639A successfully refreshed from Google Patents.
US4294639A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Fiber-reinforced composite wheel construction
Assignee: Wachovia Capital Finance Corp Central
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Filing: 1980-02-06
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Granted: 1981-10-13
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Expires: 2000-02-06
Abstract
Abstract A fiber-reinforced composite vehicle wheel, and a method and apparatus for construction thereof. The wheel comprises a disc portion having reinforcing fibers in substantially random orientation disposed predominantly in planes perpendicular to the wheel axis, and a rim portion having directional first reinforcing fibers substantially parallel to each other and oriented circumferentially of or substantially parallel to the wheel axis, or both, and second reinforcing fibers which are substantially randomly oriented circumferentially of the wheel axis. The method includes formation of separate rim and disc charges from sheet molding plastic resin compound and compression molding of the charges to form an integral composite rim and disc structure of essentially homogeneous resin reinforced by the fibers. An apparatus for molding the wheel features radially movable rim mold sections and axially reciprocable disc mold sections all having mold surface contours for forming a molded composite wheel of desired configuration.
Inventors
- 👤 James A. Woelfel
- 👤 Richard W. Smith
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-27 18:51
CPC Classifications
B; B29; B29C; B29C53/00; B29C53/56; B29C53/58; B29C53/60; B29C70/00; B29C70/003; B29C70/04; B29C70/06; B29C70/08; B29C70/081; B29C70/28; B29C70/40; B29C70/50; B29C70/502; B60; B60B; B60B5/00; B60B5/02; B29K; B29K2309/00; B29K2309/08
Claims Analysis
Total Claims: 53
Claim 1
Independent Claim
141 words
A method of constructing a vehicle wheel of the type which includes a rim portion for mounting of a tire thereon and a disc portion for mounting the wheel to a vehicle, said method comprising the steps of: (a) coiling a first sheet section of fiber-reinforced plastic resin construction having laterally spaced parallel side edges to form a rim charge hoop consisting of at least one coil ply having said laterally spaced side edges disposed in respective axially spaced planes, (b) placing said rim charge hoop in a mold, (c) placing a separate disc charge into said mold within said rim charge hoop, said disc charge comprising at least one second sheet section of fiber-reinforced plastic resin construction, (d) compression molding said rim and disc charge to form an integral fiber-reinforced composite wheel, and (e) removing said wheel from said mold.
Claim 2
Independent Claim
141 words
A method of constructing a vehicle wheel of the type which includes a rim portion for mounting of a tire thereon and a disc portion for mounting the wheel to a vehicle, said method comprising the steps of: (a) coiling a first sheet section of fiber-reinforced plastic resin construction having laterally spaced parallel side edges to form a rim charge hoop consisting of at least one coil ply having said laterally spaced side edges disposed in respective axially spaced planes, (b) placing said rim charge hoop in a mold, (c) placing a separate disc charge into said mold within said rim charge hoop, said disc charge comprising at least one second sheet section of fiber-reinforced plastic resin construction, (d) compression molding said rim and disc charge to form an integral fiber-reinforced composite wheel, and (e) removing said wheel from said mold.
Claim 3
Dependent Claim
46 words
The method set forth in claim 1 for constructing a wheel having bead retaining flanges at opposite axial edges of said rim, and wherein said method includes the additional step (f) prior to said step (b) of outwardly flaring axial edges of said rim charge hoop.
Claim 4
Independent Claim
143 words
A method of constructing a vehicle wheel of the type which includes a rim portion for mounting of a tire thereon, bead retaining flanges at opposite axial edges of said rim, and a disc portion for mounting the wheel to a vehicle, said method comprising the steps of: (a) coiling a first sheet section of fiber reinforced plastic resin construction to form a rim charge hoop consisting of at least one coil ply, (b) outwardly flaring axial edges of said rim charge hoop, (c) placing said rim charge hoop in a mold, (d) placing a disc charge into said mold within said rim charge hoop, said disc charge comprising at least one second sheet section of fiber-reinforced plastic resin construction, (e) compression molding said rim and disc charge to form an integral fiber-reinforced composite wheel, and (f) removing said wheel from said mold.
Claim 5
Independent Claim
143 words
A method of constructing a vehicle wheel of the type which includes a rim portion for mounting of a tire thereon, bead retaining flanges at opposite axial edges of said rim, and a disc portion for mounting the wheel to a vehicle, said method comprising the steps of: (a) coiling a first sheet section of fiber reinforced plastic resin construction to form a rim charge hoop consisting of at least one coil ply, (b) outwardly flaring axial edges of said rim charge hoop, (c) placing said rim charge hoop in a mold, (d) placing a disc charge into said mold within said rim charge hoop, said disc charge comprising at least one second sheet section of fiber-reinforced plastic resin construction, (e) compression molding said rim and disc charge to form an integral fiber-reinforced composite wheel, and (f) removing said wheel from said mold.
Claim 6
Dependent Claim
30 words
The method set forth in claim 1 wherein said first and second sheet sections each comprise fiber strands and resin in a ratio of less than 80% fibers by weight.
Claim 7
Dependent Claim
19 words
The method set forth in claim 4 wherein said ratio is on the order of 50% fibers by weight.
Claim 8
Dependent Claim
27 words
The method set forth in claim 1 wherein said fibers in said rim charge hoop include at least first directional fibers oriented substantially circumferentially of said hoop.
Claim 9
Dependent Claim
25 words
The method set forth in claim 6 wherein fibers in said unidirectional portion of said first directional fibers are intermittently discontinuous circumferentially of said hoop.
Claim 10
Dependent Claim
25 words
The method set forth in claim 7 wherein said fibers in said rim charge hoop further include random fibers oriented randomly of the hoop axis.
Claim 11
Dependent Claim
27 words
The method set forth in claim 8 wherein said fibers in said rim charge hoop further comprise second directional discontinuous fibers oriented substantially axially of said hoop.
Claim 12
Dependent Claim
31 words
The method set forth in claim 8 or 9 wherein the ratio of said directional fibers to said random fibers is in the range of 5/45 to 45/5 directional/random by weight.
Claim 13
Dependent Claim
21 words
The method set forth in claim 10 wherein said ratio is in the range of 20/30 to 30/20 directional/random by weight.
Claim 14
Dependent Claim
39 words
The method set forth in claim 11 wherein said random fibers are in the range of 1.25 cm to 10 cm in length and said directional fibers are in the range of 5 cm to 30 cm in length.
Claim 15
Dependent Claim
33 words
The method set forth in claim 12 wherein said random fibers are on the order of 5 cm in length and said directional fibers are on the order of 20 cm in length.
Claim 16
Dependent Claim
33 words
The method set forth in claim 1, 8 or 9 wherein fibers in said disc charge sections are oriented substantially randomly in each charge section essentially in planes perpendicular to the wheel axis.
Claim 17
Dependent Claim
28 words
The method set forth in claim 14 wherein said random fibers in said disc charge section are in the range of 1.25 cm to 10 cm in length.
Claim 18
Dependent Claim
25 words
The method set forth in claim 15 wherein said random fibers in said disc charge section are on the order of 2.5 cm in length.
Claim 19
Dependent Claim
26 words
The method set forth in claim 1 wherein said fibers in said rim charge hoop include directional first fibers oriented substantially axially of the hoop axis.
Claim 20
Dependent Claim
26 words
The method set forth in claim 17 wherein said fibers in said rim charge hoop further include second fibers oriented substantially randomly of said hoop axis.
Claim 21
Dependent Claim
28 words
The method set forth in claim 18 wherein said fibers in said rim charge hoop further include directional discontinuous third fibers oriented substantially circumferentially of the hoop axis.
Claim 22
Dependent Claim
34 words
The method set forth in claim 18 or 19 wherein said directional and random fibers are disposed essentially in separate layers with the outer-most layer in said rim charge hoop being of directional fibers.
Claim 23
Dependent Claim
28 words
The method set forth in claim 1 comprising the additional step of (f) finishing said wheel by removing flash from around the edges of the wheel as molded.
Claim 24
Dependent Claim
69 words
The method set forth in claim 21 for constructing a wheel having a circular array of openings around the disc portion to lend a spoked configuration to the wheel wherein said step (d) includes the step of molding at each desired opening location a pocket integral with but offset from said disc portion, and wherein said step (f) includes the step of removing said pockets to form said openings.
Claim 25
Dependent Claim
29 words
The method set forth in claim 21 or 22 wherein said step (f) includes the additional step of drilling a circular array of bolt holes in said disc portion.
Claim 26
Dependent Claim
69 words
The method set forth in claim 2 or 3 for constructing a wheel having a central hub portion extending axially from said disc portion, and wherein said disc charge includes a first number of sheet sections having outer edges adjacent said hoop for forming said disc portion and a second number of smaller sheet sections layered axially of said first number of sheet sections for forming said hub portion.
Claim 27
Independent Claim
168 words
A method of constructing a fiber-reinforced composite wheel having integral rim and disc portions comprising the steps of: (a) coiling a continuous flat strip of fiberreinforced plastic resin to form a rim charge hoop of multiple spiral plies, (b) placing said rim charge hoop between radially opened rim mold sections, (c) closing said rim mold sections, (d) cutting a plurality of substantially square sheet sections of fiber-reinforced plastic resin and placing said sheet sections in a coaxial stack on the face of a first section of a disc mold substantially coaxially with said rim mold section with section corners circumferentially staggered so as to obtain maximum coverage of said mold section face, (e) closing said disc mold by displacing said first disc mold section and a second disc mold section to axially opposed positions whithin said rim mold sections, (f) compression molding said wheel to form an integral essentially homogeneous plastic rim and disc structure reinforced by said fibers, and (g) removing said wheel from said mold sections.
Claim 28
Independent Claim
168 words
A method of constructing a fiber-reinforced composite wheel having integral rim and disc portions comprising the steps of: (a) coiling a continuous flat strip of fiberreinforced plastic resin to form a rim charge hoop of multiple spiral plies, (b) placing said rim charge hoop between radially opened rim mold sections, (c) closing said rim mold sections, (d) cutting a plurality of substantially square sheet sections of fiber-reinforced plastic resin and placing said sheet sections in a coaxial stack on the face of a first section of a disc mold substantially coaxially with said rim mold section with section corners circumferentially staggered so as to obtain maximum coverage of said mold section face, (e) closing said disc mold by displacing said first disc mold section and a second disc mold section to axially opposed positions whithin said rim mold sections, (f) compression molding said wheel to form an integral essentially homogeneous plastic rim and disc structure reinforced by said fibers, and (g) removing said wheel from said mold sections.
Claim 29
Independent Claim
166 words
A method of constructing a fiber-reinforced composite wheel having integral rim and disc portions comprising the steps of: (a) edgewise coiling a flat strip of fiber-reinforced plastic resin to form a rim charge of multiple spiral plies of progressively increasing radius, (b) placing said rim charge between radially opened rim mold sections, (c) closing said rim mold sections, (d) stacking flat sheet sections of fiber-reinforced plastic resin as a disc charge on the face of a first section of a disc mold substantially coaxially with said rim mold section with said sheet sections of said disc charge lying essentially in planes radially of said rim charge, (e) closing said disc mold by displacing both said first disc mold section and a second disc mold section to axially opposed positions within said rim mold sections, (f) compression molding said charges to form a wheel comprising an integral essentially homogeneous resin rim and disc structure reinforced by said fibers, and (g) removing said wheel from said mold sections.
Claim 30
Independent Claim
166 words
A method of constructing a fiber-reinforced composite wheel having integral rim and disc portions comprising the steps of: (a) edgewise coiling a flat strip of fiber-reinforced plastic resin to form a rim charge of multiple spiral plies of progressively increasing radius, (b) placing said rim charge between radially opened rim mold sections, (c) closing said rim mold sections, (d) stacking flat sheet sections of fiber-reinforced plastic resin as a disc charge on the face of a first section of a disc mold substantially coaxially with said rim mold section with said sheet sections of said disc charge lying essentially in planes radially of said rim charge, (e) closing said disc mold by displacing both said first disc mold section and a second disc mold section to axially opposed positions within said rim mold sections, (f) compression molding said charges to form a wheel comprising an integral essentially homogeneous resin rim and disc structure reinforced by said fibers, and (g) removing said wheel from said mold sections.
Claim 31
Dependent Claim
50 words
The method set forth in claim 26 wherein said step (d) includes the steps of: (d1) cutting a plurality of substantially square sheet sections, and (d2) placing said sheet sections in a coaxial stack with section corners circumferentially staggered so as to obtain maximum coverage of said mold section face.
Claim 32
Dependent Claim
38 words
The method set forth in claim 27 or 25 for constructing a wheel having bead retaining flanges comprising the additional step (h) prior to said step (b) of outwardly flaring opposite axial edges of said rim charge hoop.
Claim 33
Dependent Claim
78 words
The method set forth in claim 27 for constructing a wheel which includes a circular array of openings around the disc portion to lend a spoked appearance to the wheel as a whole wherein said step (f) includes the step of molding at each opening location a pocket integral with but offset from said disc portion, and wherein said method includes the further step of (h) removing said pockets from the wheel as molded to form said openings.
Claim 34
Dependent Claim
46 words
The method set forth in claim 29 wherein said disc portion is imperforate in the wheel as molded, and wherein said method further comprises the step of (i) opening a circular array of mounting holes in said disc portion for mounting said wheel on a vehicle.
Claim 35
Independent Claim
128 words
A method of constructing a vehicle wheel of the type having a rim portion having at least one rim flange for mounting of a tire and a disc portion for mounting the wheel to a vehicle, said method comprising the steps of: (a) coiling a first sheet section of fiberglass reinforced plastic resin to form a rim charge hoop of at least one spiral ply, (b) outwardly flaring at least one edge of said rim charge hoop, (c) placing said rim charge hoop in a mold, (d) placing in said mold within said rim charge hoop at least one second sheet section of fiberglass reinforced plastic resin to form a disc charge, and (e) compression molding said disc and rim charges from an integral fiberglass reinforced plastic wheel.
Claim 36
Independent Claim
128 words
A method of constructing a vehicle wheel of the type having a rim portion having at least one rim flange for mounting of a tire and a disc portion for mounting the wheel to a vehicle, said method comprising the steps of: (a) coiling a first sheet section of fiberglass reinforced plastic resin to form a rim charge hoop of at least one spiral ply, (b) outwardly flaring at least one edge of said rim charge hoop, (c) placing said rim charge hoop in a mold, (d) placing in said mold within said rim charge hoop at least one second sheet section of fiberglass reinforced plastic resin to form a disc charge, and (e) compression molding said disc and rim charges from an integral fiberglass reinforced plastic wheel.
Claim 37
Independent Claim
129 words
A method of constructing a vehicle wheel of the type having a rim portion for mounting of a tire and a disc portion for mounting the wheel to a vehicle, said method comprising the steps of: (a) coiling a first sheet section of fiberglass reinforced plastic resin to form a rim charge hoop of at least one spiral ply having laterally spaced longitudinal edges of said first sheet section disposed in parallel planes spaced axially of said hoop, (b) placing said rim charge hoop in a mold, (c) placing in said mold within said rim charge hoop at least one second sheet section of fiberglass reinforced plastic resin to form a disc charge, and (d) compression molding said disc and rim charges from an integral fiberglass reinforced plastic wheel.
Claim 38
Independent Claim
129 words
A method of constructing a vehicle wheel of the type having a rim portion for mounting of a tire and a disc portion for mounting the wheel to a vehicle, said method comprising the steps of: (a) coiling a first sheet section of fiberglass reinforced plastic resin to form a rim charge hoop of at least one spiral ply having laterally spaced longitudinal edges of said first sheet section disposed in parallel planes spaced axially of said hoop, (b) placing said rim charge hoop in a mold, (c) placing in said mold within said rim charge hoop at least one second sheet section of fiberglass reinforced plastic resin to form a disc charge, and (d) compression molding said disc and rim charges from an integral fiberglass reinforced plastic wheel.
Claim 39
Dependent Claim
46 words
The method set forth in claim 32 for constructing a wheel which includes at least one rim flange, said method comprising the additional step of (e) outwardly flaring at least one edge of said rim charge hoop before placing said rim charge hoop in said mold.
Claim 40
Dependent Claim
34 words
The method set forth in claim 32 or 31 wherein said step (a) comprises the step of coiling said sheet section on edge to form a plurality of hoop plies of progressively increasing radius.
Claim 41
Dependent Claim
34 words
The method set forth in claim 1 or 32 wherein said first sheet sections possess a width dimension between said side edges which approximates the desired axial width of the wheel rim as molded.
Claim 42
Dependent Claim
28 words
The method set forth in claim 35 wherein said second sheet sections are placed within said mold in planes perpendicular to the axis of said rim charge hoop.
Claim 43
Independent Claim
109 words
A method of constructing a fiber-reinforced composite wheel having integral rim and disc portions comprising the steps of: (a) stacking a plurality of flat sheet sections of fiber-reinforced plastic resin on one face of a wheel mold substantially coaxially with said mold by cutting a plurality of substantially square sheet sections and then placing said sheet sections in a coaxial stack with section corners circumferentially staggered so as to obtain maximum coverage of said one face, (b) closing said wheel mold, (c) compression molding said wheel to form an integral essentially homogenous plastic rim and disc structure reinforced by said fibers, and (d) removing said wheel from said mold.
Claim 44
Independent Claim
109 words
A method of constructing a fiber-reinforced composite wheel having integral rim and disc portions comprising the steps of: (a) stacking a plurality of flat sheet sections of fiber-reinforced plastic resin on one face of a wheel mold substantially coaxially with said mold by cutting a plurality of substantially square sheet sections and then placing said sheet sections in a coaxial stack with section corners circumferentially staggered so as to obtain maximum coverage of said one face, (b) closing said wheel mold, (c) compression molding said wheel to form an integral essentially homogenous plastic rim and disc structure reinforced by said fibers, and (d) removing said wheel from said mold.
Claim 45
Independent Claim
109 words
A method of compression molding a fiber reinforced composite rim for a vehicle wheel comprising the steps of (a) providing a mold having radially reciprocable first mold sections and axially reciprocable second mold sections with all of said mold sections cooperating to form a cavity for compression molding of a wheel rim including bead retaining flanges, (b) forming a rim mold charge comprising a hoop of fiber-reinforced resin sheet molding compound coiled on edge, (c) with all said mold sections open, placing said rim charge hoop within said mold and then closing said mold sections under heat and pressure, (d) opening said mold sections, and (e) removing said rim.
Claim 46
Independent Claim
109 words
A method of compression molding a fiber reinforced composite rim for a vehicle wheel comprising the steps of (a) providing a mold having radially reciprocable first mold sections and axially reciprocable second mold sections with all of said mold sections cooperating to form a cavity for compression molding of a wheel rim including bead retaining flanges, (b) forming a rim mold charge comprising a hoop of fiber-reinforced resin sheet molding compound coiled on edge, (c) with all said mold sections open, placing said rim charge hoop within said mold and then closing said mold sections under heat and pressure, (d) opening said mold sections, and (e) removing said rim.
Claim 47
Dependent Claim
24 words
The method set forth in claim 38 comprising the additional step prior to said step (c) of: (f) flaring axial ends of said hoop.
Claim 48
Dependent Claim
112 words
The method set forth in claim 38 or 39 wherein said step (c) comprises the steps of: (c1) placing said rim charge hoop within said mold and then closing said first mold sections so as to capture said rim charge hoop within said mold with axial ends of said rim charge mold extending into portions of said mold cavity for forming said bead retaining flanges, and then (c2l ) closing said second mold sections such that material for forming said bead retaining flanges is captured within said portions of said mold cavity rather than forced under pressure to flow into said portions of said cavity by closure of said second mold sections.
Claim 49
Dependent Claim
37 words
The method set forth in claim 40 wherein said step (b) comprises the step of forming said charge hoop of sheet molding compound containing directional fibers such that said directional fibers extend generally axially of said hoop.
Claim 50
Dependent Claim
34 words
The method set forth in claim 40 wherein said second mold sections are closed in said step (c2) by displacing said second mold sections so as to reach their respective closed positions substantially simultaneously.
Claim 51
Dependent Claim
69 words
The method set forth in claim 42 comprising the additional steps of forming an open flange in said rim charge hoop and then placing said rim charge hoop into said mold with the flanged end of said hoop resting on said lower disc mold section so as to enhance location of rim charge material in said portion of said mold cavity prior to closing of said disc mold sections.
Claim 52
Independent Claim
208 words
A method of molding a vehicle wheel having at least one bead retaining flange which comprises the steps of: (a) providing a mold including at least two rim mold sections radially reciprocable with respect to a wheel axis between open and closed positions, and upper and lower disc mold sections axially reciprocable between closed positions in which said disc mold sections cooperate with said rim mold section to form a mold cavity and open positions wherein both of said disc mold sections are spaced from their respective closed positions, opposing surface portions of said lower disc mold section and said rim mold sections cooperating to form a portion of said cavity for molding said flange, (b) locating a rim charge hoop in said mold by placing said rim charge hoop on said lower disc mold with said disc and rim mold sections open and then closing said rim mold sections such that a portion of said rim charge hoop is located in said mold cavity portion for forming said rim flange, (c) placing a disc charge on said lower disc mold section, and then (d) closing said disc mold sections by displacing said disc mold sections toward each other so as to reach said closed positions substantially simultaneously.
Claim 53
Independent Claim
208 words
A method of molding a vehicle wheel having at least one bead retaining flange which comprises the steps of: (a) providing a mold including at least two rim mold sections radially reciprocable with respect to a wheel axis between open and closed positions, and upper and lower disc mold sections axially reciprocable between closed positions in which said disc mold sections cooperate with said rim mold section to form a mold cavity and open positions wherein both of said disc mold sections are spaced from their respective closed positions, opposing surface portions of said lower disc mold section and said rim mold sections cooperating to form a portion of said cavity for molding said flange, (b) locating a rim charge hoop in said mold by placing said rim charge hoop on said lower disc mold with said disc and rim mold sections open and then closing said rim mold sections such that a portion of said rim charge hoop is located in said mold cavity portion for forming said rim flange, (c) placing a disc charge on said lower disc mold section, and then (d) closing said disc mold sections by displacing said disc mold sections toward each other so as to reach said closed positions substantially simultaneously.
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USPTO Annuity & Maintenance Windows
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| 3.5 Years (Year 4) | 1984-10-12 | 1985-04-13 | 1985-10-13 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1988-10-12 | 1989-04-13 | 1989-10-13 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1992-10-12 | 1993-04-13 | 1993-10-13 | $7700.00 | Window Closed / Lapsed |