Rim for a wheel

A wheel suitable for a 4-wheeled vehicle or a motorbike 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 into at least the first flange and the barrel, and being capable of bearing the 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
• (a) a protective insert 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, wherein the rim comprises an outer layer also bound by the polymer matrix, wherein the outer layer forms a covering on the protective insert and the outer layer comprises carbon fibres, and
• (b) wherein at least a portion of the first bead seat is spaced apart from the primary structural component, and 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, and wherein either:
• (i) the primary structural component, in the first flange, splits in the area under the bead seat, and the filler material is located in a cavity formed by the split, and a portion of the primary structural component disposed most radially outward forms part of the bead seat, together with the outer layer, and the filler material is located between this portion and a portion of the primary structural component located most radially inward;
• or
• (ii) the outer layer forms the bead seat with the resin and the bead seat does not include carbon fibres of the primary structural component.

A method for making a non-metallic rim for a wheel suitable for a 4-wheeled vehicle or a motorbike, the method comprising:

• assembling a primary structural component with a first bead seat, a second bead seat and, a protective insert, a filler material and an outer layer;
• and
• binding the primary structural component, bead seats, protective insert, filler material and outer layer 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, the first bead seat and the second bead seat, each arranged axially inwardly, respectively, of the first and second flanges;
• the primary structural component comprising carbon fibres and configured to extend into at least the first flange and the barrel, and being capable of bearing the 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
• (a) the protective insert is disposed between an 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, wherein the rim comprises an outer layer also bound by the polymer matrix, wherein the outer layer forms a covering on the protective insert and the outer layer comprises carbon fibres;
• and
• (b) at least a portion of the first bead seat is spaced apart from the primary structural component, and the outer layer forms at least part of the bead seat, the filler material, which is 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, and wherein either:
• (i) the primary structural component, in the first flange, splits in the area under the bead seat, and the filler material is located in a cavity formed by the split, and a portion of the primary structural component disposed most radially outward forms part of the bead seat, together with the outer layer, and the filler material is located between this portion and a portion of the primary structural component located most radially inward;
• or
• (ii) the outer layer forms the bead seat with the resin and the bead seat does not include carbon fibres of the primary structural component.