THIS INVENTION relates to a motor vehicle wheel frame, ie a frame of a road wheel for a mechanically powered vehicle or motor vehicle. It relates also to a method of forming a side member of such a motor vehicle wheel frame, and to a side member of such a motor vehicle wheel frame.

For purposes of this specification, the term 'wheel frame' shall be used to denote a portion of a tyred road wheel without the tyre, ie that portion of the wheel which is colloquially, but incorrectly, referred to as a ' im' .

The kind of wheel frame to which this invention relates is formed generally of first and second side members of moulded synthetic polymeric material, each side member comprising, at an outer periphery thereof, a rim formation, and at an inner periphery thereof, a hub mounting formation for mounting hub components forming a hub of a wheel frame.

The side members are secured side by side, the rim is formed, and the hub components are assembled - not necessarily in that order - to render the wheel frame ready to receive a tyre and for rotational mounting about an axle.

This invention is concerned more particularly with mounting of a flange, intended to form part of the hub, to a side member.

In accordance with a first aspect of this invention, there is provided a method of forming a side member of a vehicle wheel frame of the general kind to which this invention relates, including the method steps of laying up a number of layers of fibrous material having resin applied thereto in forming the side member of the vehicle wheel frame; forming a central opening in the side member being formed; placing a generally circular flange, forming part of hub components to form a hub, against material radially outwardly of the opening and centring the flange in relation to the side member by means of a jig or template,- laying up a number of additional layers of fibrous material having resin applied thereto over the flange and material surrounding the flange; curing the assembly thus formed together with the jig or template; and removing the jig or template when curing has at least partially been completed.

The method may include placing the flange against a side, which will in use be an inner side, of the side member, and superimposing the additional layers on said inner side.

Advantageously, the method may include providing a peripherally recessed region in the flange, and pressing portions of said additional layers into said peripherally recessed portion to anchor the flange on the side member.

The method may include applying pressure on the flange by means of the jig or template to press the flange against said material radially outwardly of the opening to conform said material radially outwardly of the opening to the surface of the flange. Said resin may be a heat setting resin.

In accordance with a second aspect of this invention, there is provided a side member intended to form part of a motor vehicle wheel frame of the general kind to which this invention relates, the side member being in the form of a moulding of synthetic polymeric material formed of a plurality of layers of fibrous material bonded together by resin, the side member mounting a generally circular flange centrally in a central opening in the side member, the flange being located via an annular flange formation thereof intermediate a first number of said plurality of layers of the fibrous material and an additional number of said plurality of layers of the fibrous material.

Advantageously, the flange may include a peripherally recessed region, portions of at least some of said additional layers being anchored in said peripheral recess.

By way of development, said flange may be in the form of an anchor member and may include a plurality of circumferentially spaced securing formations suitable for securing an external hub component.

In accordance with a third aspect of this invention, there is provided a vehicle wheel frame of the general kind to which this invention relates, the vehicle wheel frame comprising a pair of side members, in accordance with the second aspect of this invention, which side members are arranged in opposing side by side configuration, the respective flanges being coaxially opposed to form a hub or part of a hub of the vehicle wheel frame, and the rim portions being connected together to form a rim for a tyre.

When the flanges of the side members are in the form of anchor members and include a plurality of circumferentially spaced securing formations, the wheel frame may further comprise external hub components secured to said flanges.

The invention is now described by way of examples with reference to the accompanying diagrammatic drawings.

In the drawings:

Figure 1 shows, in diametrical section, one portion, comprising mostly a side member, of a first embodiment of a vehicle wheel frame in accordance with the invention,- Figure 2 shows, in a corresponding view, to a larger scale, mounting of a flange to the side member;

Figure 3 shows, in a view corresponding to Figure 1, but fragmentarily and to a larger scale, a portion of a second embodiment of a vehicle wheel frame in accordance with the invention; and

Figure 4 shows, fragmentarily in front view, the embodiment of Figure 3.

With reference to Figure 1 of the drawings, a vehicle wheel frame in accordance with the invention is shown fragmentarily by reference numeral 10. The wheel frame 10 comprises a pair of side members, of which one only is shown at 12, arranged in opposing side by side configuration.

Each side member 12 forms a plurality of spokes 20. In Figure 1, the upper portion of the drawing shows a section through a spoke, and the lower portion of the drawing shows a section between spokes. At their radially outer ends, the spokes 20 support a peripheral ring formation 22. The ring formations 22 of the side members 12 support an annular rim portion 14 shaped to receive a tyre.

Toward the radially inner ends, the spokes 20 support hub mounting formations 24 comprising a peripheral, outwardly bulged boss formation 26 extending into a generally radial annulus 28. A central aperture 30 is defined by the annulus 28.

In accordance with the invention, a flange 32 forming part of a hub 16 is bonded to the hub mounting formations 24 to enable the vehicle wheel frame 10 with its tyre rotationally to be mounted about an axle providing a rotation axis 18.

With reference also to Figure 2, the flange 32 has a radially outwardly extending flange formation 34 including a plane annular surface 36. At a peripherally outer and axially inner region of the flange formation 34, a curved peripheral recess 38 is formed.

Whereas the side member 12 and the annular rim portion 14 are in the form of mouldings of synthetic polymeric material, the flange 32 may advantageously be of steel, or a lightweight metal or metal alloy.

During manufacture, the side member 12 is formed by laying a plurality of layers of fibrous material containing resin onto a mould. The central aperture 30 is formed in the layers of material forming the side member 12, and the flange 32 is centrally placed within the central aperture 30 such that the plane annular surface 36 interfaces with the inside of the

annulus 28. A layer 42 of resin is present at the interface between the flange formation 34 and the annulus 28. The layer 42 can be provided separately, or resin already in or on the fibrous material can be used also for bonding between the flange formation 34 and the annulus 28.

The flange 32 is centred by means of a jig or template which may conveniently be mounted to the mould on which the side member 12 is formed.

A plurality of layers 44 of fibrous material containing resin is placed one by one over an inside surface of the side member 12 and pressed into the peripheral recess 38 as shown at 46.

With the jig or template still in position, the side member 12 is cured. After curing, the jig or template and the mould are removed and the side member 12 which now integrates the flange 32 can be mated to a similar side member integrating a flange together with the annular rim portion 14 and other hub components to form the vehicle wheel frame 10.

It is an advantage that a flange of a material such as metal which can be premachined is integrated into a moulded side member during the moulding process. Thus, the flange 32 effectively forms part of the mould in respect of the annulus 28. Thus, no machining or working other than cutting the central aperture 30

is performed on the side member 12. Such cutting is an extremely simple operation which can, for example, be performed by means of a knife, a blade, or the like. This brings about the advantage that all of the layers of fibrous material remain intact and the fibres are not severed. This facilitates obtaining an optimised strength-to-mass ratio for the moulding material. It is important that a machining operation with the associated setting up time, the need for a machine, and the like are obviated.

It is also believed that a saving in labour and time is obtained in accordance with the invention.

A developed embodiment of a wheel frame is illustrated in Figures 3 and 4, indicated by reference numeral 110. It is similar to the embodiment of Figures 1 and 2 and is not again described fully. Like reference numerals denote like components or features. Merely a development over the first embodiment will be described.

The flange 132 is in the form of an anchor member and includes a plurality of tapped holes 148 on a pitch circle diameter. A hub member 150 is externally secured to the anchor member 132 by means of counter sunk screws. To this end, the hub member has a flange 152 having countersunk holes 154 on the same pitch circle diameter and at the same circumferential spacing

than the tapped holes 148, and is secured to the flange 132 in side-by-side relationship.

A superimposed, spider formation 156 (best perceived from Figure 2) and which is integral with the flange 152 has a plurality of tapped holes 158 on which wheel components, such as discs for disc brakes, can be secured.

The hub member 150 has a central aperture 160 to pass an axle, and a bearing seat 162. It has an inwardly directed annular spigot 164 seating inside the central aperture 130 of the flange 132 for locating and centring the hub member 150.

The embodiment of Figures 3 and 4 has the same advantages as that of Figures 1 and 2. Additionally, it allows dedicated hub members 150, respectively suitable for different models of vehicles, to be secured to common side members, of which only one or only a limited number of variants need be manufactured or kept in stock. Thus, for each different model, a hub member is provided which hub member has a standard interface for mounting to the flange 132, and dedicated or special features as required for the specific model.