FR3071772A1 - ALUMINUM WHEEL FOR MOTOR VEHICLE - Google Patents

Abstract

Aluminum wheel (1) for a motor vehicle comprising a rim (2) defining an outer face of the wheel and an inner face and a web (3) formed integrally with the rim on the side of the outer face, the wheel further comprising a reinforcement (9) of composite material comprising a woven structure and a matrix of polymeric material, the reinforcement (9) being adhered to the web (3) by an adhesive.

Description

ALUMINUM WHEEL FOR MOTOR VEHICLE The invention is in the field of wheels for motor vehicles.

Wheels for motor vehicles are known which are formed from steel, aluminum or even composite materials.

The foundry or forging processes, applied to aluminum, offer a possibility of creating a style on the visible face of the wheel, to give it elegance, a guarantee of attractiveness for buyers and users. .

But aluminum wheels for foundry or forging are heavy and the manufacturing process is expensive.

Conversely, the wheels made of sheet steel or aluminum are inexpensive, but their manufacture does not make it possible to offer a style on the visible face of the wheel, which implies providing a hubcap, which is an expensive add-on and adding to the weight.

The composite material wheels are very expensive.

We are interested in aluminum wheels allowing the obtaining of a low weight, for a large diameter, and for this dimensioned to the just necessary. We speak of a structural aluminum wheel, since the aluminum material is used only for the purpose of defining a basic structure for the wheel. They may have limited mechanical performance or also limited performance in terms of life cycle analysis. In addition, it may be necessary to add a hubcap as part of the styling.

We know from document US5433511 wheels reinforced with a composite metal matrix, which is restrictive in the manufacturing process.

The invention aims to improve the mechanical and acoustic performance of the aluminum wheels thus mentioned without significantly increasing their mass, and if possible by offering an alternative to the use of a hubcap (styling).

For this, an aluminum wheel for a motor vehicle is proposed comprising a rim defining an external face of the wheel and an internal face of the wheel and a web formed integrally with the rim on the side of the external face, characterized in that that the wheel further comprises a reinforcement of composite material comprising a woven structure and a matrix of polymeric material, the reinforcement being glued to the web by an adhesive.

According to optional characteristics:

- said polymeric material is a thermosetting resin;

- said polymeric material is a thermoplastic resin;

- said reinforcement is bonded to the outer side of the veil;

- said reinforcement is bonded to the internal side of the veil;

- Said reinforcement is glued to one side of the web, the latter consisting of concentric spokes on the edges of which the reinforcement is also glued, the reinforcement extending beyond the slices so as to be glued on both sides veil;

- The woven structure can be made of carbon fibers, glass, or even Kevlar.

There is also proposed a method of manufacturing an aluminum wheel for a motor vehicle, comprising a step of forming the structure of the wheel to minimize its mass, then a step of bonding the reinforcement to the web by heating the adhesive in a press in which the wheel is placed with the reinforcement on the web.

There is also proposed a motor vehicle comprising an aluminum wheel as mentioned above.

The invention will be better understood, and other objects, characteristics, details and advantages thereof will appear more clearly in the explanatory description which follows, made with reference to the accompanying drawings given solely by way of example illustrating several embodiments of the invention and in which:

- Figures 1 and 2 are views of a first embodiment;

- Figures 3 to 5 are views of a second embodiment;

- Figures 6 to 8 are views of a third embodiment.

In Figure 1 there is shown an aluminum wheel 1 comprising a rim 2 and a web 3 arranged around a circular surface 4, central through which holes for the wheel studs 6 and a passage for the rocket 5.

The circular surface 4 is visible on the inner face of the web 3, the latter being attached to one of the faces of the rim 2, intended to be positioned outside the vehicle.

In the embodiment which is presented, the web 3 is composed of a set of five spokes of equal length regularly arranged from the circular surface 4 towards the rim 2.

A patch 9 of composite materials is approached from the web 3 by the face of the rim 2 opposite the web 3, and is applied, inside the wheel 1, against the web 3 around the circular surface 4.

The patch 9 has, like the veil 3, a shape in five rays of equal lengths arranged regularly around a central orifice 8 whose size corresponds to that of the circular surface 4.

In Figure 2, we see the patch 9 in place on the web 3, inside the wheel 1, on the inner face of the web 3.

The holes for the wheel stud 6 are free, as is the passage for the rocket 5. The circular surface 4 is not coated with patch 9, however the five spokes of the web 3 are each coated with patch 9. Patch 9 can be folded over the edges of veil 3 (not visible).

In Figure 3, there is shown a second embodiment of the invention. This time, a patch 19 is applied to the outer face of the web 13 of a wheel 11. This has a rim 12 on one side of which the web 13 is fixed. The web 13 again takes the form of five spokes of equal length around a central surface in which are formed holes for the wheel studs 16 and a passage for the rocket

15. Patch 19 comprises five spokes of equal length around a substantially solid central surface but in which five holes 18 are made, the size of which is similar to that of the holes for the wheel studs 16.

As shown in Figure 4, the patch 19 is applied to the outer face of the web 13, outside of the wheel 11 and folded over the edges of the web 13. The hole for the passage of the rocket is covered by patch 19, but on the other hand, the holes for the wheel studs 16 are left free thanks to the presence of the orifices 18 in the surface of patch 19.

In Figure 5, there is shown in section the application of patch 19 on the wheel 11. The section is a broken section along the planes of two spokes of the web 13, as mentioned in Figure 4 (reference V). There are two wheel stud holes 16 and the passage for the rocket 15.

As can be seen, the thickness of patch 19 is extremely small compared to the thickness of the material, in this case aluminum, of the web 13 of the wheel 11.

In Figures 6 and 7, there is shown a third embodiment of the invention. A patch 29 consists of a set of five branches of equal length regularly spaced around a central surface. Each of the branches carries lateral fins 30. The central part carries orifices 28 corresponding as previously to the holes for the wheel studs (referenced 26 in FIG. 7).

In Figure 7, more specifically, is shown the wheel 21 on which is applied the patch 29. The outer surface of the web 23 connected to one of the faces of the rim 22 is covered by the patch 29. The hole for rocket is invisible, but on the other hand, the holes for wheel stud 26 are free, thanks to the orifices 28 positioned at their level. The patch 19 is folded over the edges of the veil 23.

In Figure 8, there is shown the inside of the wheel 21, according to the angle of view VIII indicated in Figure 7, and we see that on a section of each of the branches of the veil 23, the fins 30 of the patch 29, folded back beyond the edge of the web 23, cover the internal surface of the web 23. The left and right fins are dimensioned so as to meet on the internal face of the web 23.

In this figure, we can see the passage 25 for the rocket, but it is obscured on the outer side of the wheel 21 by the patch 29. We also see the holes for wheel stud 26, and these , unlike the rocket passage 25 are not obscured.

It is specified that in each of these embodiments (Figures 1 to 8) the patch 9, 19 or 29 is composed of a stack of fabrics of the glass fiber or carbon fiber type, the fabrics being pre-impregnated thermosetting or thermoplastic resin. It is specified that the patch can be composed of several layers stacked one on the other according to several orientations of the fibers. It has a thickness of less than 1 mm.

The wheel 1, 11,21 is manufactured by a foundry or forging process.

The fabric stack is then positioned on the wheel with a film of adhesive between the surface of the web 3, 13 or 23 and the patch 9, 19 and 29.

The adhesive film can be incorporated in a fixed manner in the patch 9, 19 or 29 before its installation or be a free film, positioned between the patch and the material of the wheel, in the mold. Whichever choice is made, the assembly consisting of the aluminum wheel of the adhesive and the patch are positioned in a mold, which is then placed under a press which is closed. Once the press is closed, a heating operation completes the cooking of the assembly consisting of the aluminum wheel, the adhesive and the patch and achieves adhesion between the patch and the wheel. This heating is carried out well below the temperature which would be used for a foundry operation.

Thanks to this way of doing things, an aluminum wheel is obtained with improved mechanical and acoustic performance, without, however, its mass being significantly increased.

In the case where the patch 9, 19 or 29 used is a carbon fiber patch, it provides a styling effect which allows the wheel to be used directly without using expensive styling and whose implementation is time consuming. In the embodiment of Figures 1 and 2, it is however invisible once mounted on the wheel and therefore does not participate in its aesthetics.

Furthermore, the wheel thus obtained has a favorable life cycle analysis, and good acoustic performance.

The improvement in the mechanical performance of the wheel is particularly appreciable in the case of a sports vehicle.

The implementation of the patch can be done on certain wheels intended for certain markets, and not be carried out on other wheels intended for other markets.

Claims (9)

1. Aluminum wheel (1; 11; 21) for a motor vehicle comprising a rim (2; 12; 22) defining an external face of the wheel and an internal face of the wheel and a web (3; 13; 23) formed integrally with the rim on the side of the external face, characterized in that the wheel further comprises a reinforcement (9; 19; 29) of composite material comprising a woven structure and a matrix of polymeric material, the reinforcement (9; 19; 29) being glued to the web (3; 13; 23) with an adhesive. 2. Aluminum wheel (1; 11; 21) for a motor vehicle according to claim 1, characterized in that said polymeric material is a thermosetting resin. 3. Aluminum wheel (1; 11; 21) for a motor vehicle according to claim 1, characterized in that said polymeric material is a thermoplastic resin. 4. Aluminum wheel (11) for a motor vehicle according to one of claims 1 to 3, characterized in that said reinforcement (19) is bonded to the outer side of the web (13). 5. Aluminum wheel (1) for a motor vehicle according to one of claims 1 to 3, characterized in that said reinforcement (9) is bonded to the internal side of the web (3). 6. Aluminum wheel (21) for a motor vehicle according to one of claims 1 to 3, characterized in that said reinforcement (29) is glued to one side of the web (23), the latter consisting of concentric spokes on the edges of which the reinforcement is also bonded, the reinforcement extending beyond the edges so as to be bonded on both sides of the web (23). 7. Aluminum wheel (1; 11; 21) for a motor vehicle according to one of claims 1 to 6, characterized in that the woven structure is made of carbon fibers, or glass, or kevlar. 8. A method of manufacturing an aluminum wheel (1; 11; 21) for a motor vehicle according to one of claims 1 to 7, comprising a step of forming the structure of the wheel (2, 3; 12, 13 ; 22, 23) to minimize its mass, then a step of bonding the reinforcement (9; 19; 29) on the web by heating the adhesive in a press in which the wheel (1; 11; 21) is placed with the reinforcement on the web (3; 13; 23). 9. Motor vehicle comprising an aluminum wheel according to one of claims 1 to 7.