Shaped preform for spoke portion of a composite wheel

1. A shaped preform component for a spoke portion of a composite wheel, the shaped preform comprising:

an elongate body configured to be located in the spoke portion of a composite wheel,

wherein the shaped preform component 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.

2. The shaped preform component according to claim 1 , wherein the mass addition comprises a valve.

3. The shaped preform component according to claim 1 , wherein the compressibility of the shaped preform is <1% volumetric under moulding conditions of 50 bar hydrostatic pressure.

4. The shaped preform component according to claim 1 , wherein the shaped preform has a density of between 0.3 to 3 g/cm 3 .

5. The shaped preform component according to claim 1 , wherein the shaped preform has at least one of:

Tensile Strength of between 20 to 80 MPa;

Stiffness from 1.5 to 30 GPa.

6. The shaped preform component according to claim 1 , wherein the surface of the shaped preform has a roughened surface having a roughness of at least Ra=0.2 μm.

7. The shaped preform component according to claim 1 , wherein the shaped preform is formed from: at least one layer of non-woven, isotropic or anisotropic fibres; an isotropic fibre arrangement; an orthotropic fibre arrangement; fillers; glass microspheres; ceramic microspheres; barium sulfate; hydrophobic fumed silica; epoxy resin/hardener; phenolic resin; milled carbon fibre; comminuted carbon fibre, or a combination thereof.

8. The shaped preform component according to claim 7 , wherein the shaped preform further includes 1 to 5 wt % hydrophobic fumed silica.

9. The shaped preform component according to claim 7 , wherein the shaped preform further includes 1-2 wt % hydrophobic fumed silica.

10. The shaped preform component according to claim 7 , wherein the milled carbon fibres have a length of <500 micron length.

11. The shaped preform component according to claim 1 , wherein the shaped preform is formed from:

(i) a mixture of resin, milled carbon fibre and hollow glass microspheres;

(ii) a mixture of resin, comminuted carbon fibre and hollow glass microspheres;

(iii) a mixture of resin, and hollow glass microspheres;

(iv) a mixture of resin and milled carbon fibres;

(v) a mixture of resin and comminuted carbon fibres;

(vi) a mixture of resin, milled carbon fibre and solid ceramic microspheres;

(vii) a mixture of resin, comminuted carbon fibre and solid ceramic microspheres;

(viii) a mixture of resin and solid ceramic microspheres; or

(ix) substantially resin only.

12. The shaped preform component according to claim 1 , further comprising a curable matrix material enveloping the comprising components of the shaped preform, wherein the matrix material comprises a resin based on unsaturated polyester, polyurethane, polyvinyl ester, epoxy, thermoplastics, or combinations thereof.

13. The shaped preform component according to claim 1 , having thermal properties designed to substantially match the thermal properties of the overall composite material of the spoke portion of the composite wheel that the shaped preform is configured to be included therein.

14. The shaped preform component according to claim 1 , wherein the shaped preform comprises an incomplete or under-cured preform.

15. The shaped preform component according to claim 1 , comprising a generally cuboid body.

16. The shaped preform component according to claim 15 , comprising at least two arms extending laterally outwardly of one end of the cuboid body.

17. The shaped preform component according to claim 15 , comprising at least one L-shaped end extending axially outwardly of one end of the cuboid body.

18. The shaped preform component according to claim 1 , wherein the shaped preform is integrally formed with the composite wheel.

19. A method of forming a face portion of a composite wheel, comprising:

locating the shaped preform according to claim 1 in the spoke portion of a fibre layup of the face portion of the composite wheel in a position suitable to balance a mass addition about the central axis of the face portion of the composite wheel; and

laying up composite fibre elements around the shaped preform thereby forming the pre-moulded structure of the spoke portion of the composite wheel.

20. A composite wheel including the shaped preform according to claim 1 .