DE OLIVEIRA, Marcio Aparecido (R. Presidente Juscelino Kubstcheck de Oliveria, 305Parque Hipólito, -570- Limeira- SP, 13486, BR)
T. MITSUYASSU, Fernando (R. Cabreúva, 80 Jardim Hortência, -054- Limeira- SP, 13485, BR)
FIOR, André (R. Senador Vergueiro, 1016 Apto 0, Centro -000- Limeira- SP, 13480, BR)
DE OLIVEIRA, Marcio Aparecido (R. Presidente Juscelino Kubstcheck de Oliveria, 305Parque Hipólito, -570- Limeira- SP, 13486, BR)
T. MITSUYASSU, Fernando (R. Cabreúva, 80 Jardim Hortência, -054- Limeira- SP, 13485, BR)
| CLAIMS 1. A vehicle wheel comprising: a rim having an inner peripheral surface; a center disc portion spaced radially inwardly from said inner pe- ripheral surface, said center disc portion comprising a body having a plurality of protruding portions separated from each other by curved recesses; and a plurality of structural arms with each structural arm having a first arm end attached to said inner peripheral surface of said rim at a first weld attachment interface and a second arm end received within one of said curved recesses of said stamped body, and wherein each of said second arm ends is attached to said center disc portion at a second weld attachment interface. 2. The vehicle wheel according to claim 1 wherein said plurality of structural arms comprise a plurality of discrete arms that are separately attached to said center disc portion. 3. The vehicle wheel according to claim 1 wherein each structural arm includes a body portion extending in a radial direction between said rim and said center disc portion, and wherein each of said first arm ends include a flange portion extending transversely to said radial direction to define an abutment surface that is in contact with said inner peripheral surface of said rim. 4. The vehicle wheel according to claim 1 wherein said second arm ends define a bolted joint with each of said second arm ends including a fastener aperture to receive a fastener. 5. The vehicle wheel according to claim 1 wherein at least a portion of at least one of said rim and said plurality of structural arms includes an overmolded layer of material. 6. A method of making a vehicle wheel comprising the steps of: (a) providing a steel rim, a center disc portion with curved recesses, and a plurality of structural arms; (b) positioning one arm end of each structural arm in one of the curved recesses; and (c) joining the one arm end of each structural arm to the center disc portion and joining an opposite arm end of each structural arm to an inner peripheral surface of the steel rim. 7. The method according to claim 6 including overmolding a material over at least a portion of the vehicle wheel. 8. The method according to claim 7 wherein the material comprises one of a plastic or composite material. 9. The method according to claim 6 wherein step (c) includes joining the one arm end to the center disc portion at least at two different locations. 10. The method according to claim 9 wherein joining comprises welding, mechanical or chemical attachments. |
BACKGROUND OF THE INVENTION
This invention generally relates to a wheel assembly that includes a steel rim, a center disc portion, and a plurality of discrete structural arms that attach the center disc portion to the rim. The invention further relates to overmolding a composite or plastic material on the wheel assembly to provide a desired appearance.
Traditional steel wheels have excellent resistance performance in terms of fatigue and impact. One disadvantage with these steel wheels is design flexibility from an appearance aspect as compared to that which can be provided by aluminum wheels. In order to address this issue, steel wheels have utilized plastic covers, stainless steel dads, or composite dads to improve steel wheel appearance. These additional structures are disadvantageous from a weight and cost perspective. DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT
A vehicle wheel 10 is shown in Figure 1. The vehicle wheel 10 is rotatable about an axis A and includes a rim 12, a center disc portion 14, and a plurality of structural arms 16 that connect the center disc portion 14 to the rim 12. In one example, the rim 12 comprises a standard steel rim made by known methods. The center disc portion 14 can be made from any of various manufacturing processes. For example, the center disc portion 14 can be stamped, forged, hydro-formed, low pressure injection molded, etc. In one example, the center disc portion 14 is comprised of a stamped steel. The structural arms 16 are a plurality of discrete arms that can be made from any of various materials. In one example, the structural arms 16 are made from a steel material. The structural arms 16 are initially separate components from the rim 12 and center disc portion 14 and are subsequently attached to the rim 12 and center disc portion 14 to form the vehicle wheel 10.
The center disc portion 14 includes a disc body 18 with a center aperture 20. The center aperture 20 provides centering of the wheel 10 into a vehicle hub. The shape of the center aperture can vary to better fit a specified hub configuration, (see Figures 9A-9D and 10A-10D). Figure 9A shows a center bore or aperture 20a that comprises a flange-machined pilot bore. Figure 9B shows a center aperture 20b that comprises a flanged pilot bore. Figure 9C shows a center aperture 20c that comprises a pierced pilot bore. Figure 9D shows a center aperture 2Od that comprises a machined-after pi- erced pilot bore. Figures 10A-10D respectively show different shapes 21a, 21 b, 21c, 21 d that the center aperture 20 may take.
The disc body 18 includes a plurality of protruding portions 22, such as legs for example, that extend in a radial direction outwardly relative to the center aperture 20. Between each pair of protruding portions 22 is a curved recess 24. One structural arm 16 is received within each curved recess 24.
In the example shown, the center disc portion 14 includes five protruding portions 22; however, additional protruding portions or fewer protruding portions could be used depending upon the circle formed by fastener apertures 38 in the structural arms 16.
As shown, each structural arm 16 includes an arm body 26 that extends in the radial direction between a first arm end 28 and a second arm end 30. Each first arm end 28 is attached to an inner peripheral surface 32 of the rim 12 at a first joint attachment interface 34. Each second arm end 30 is attached to the center disc portion 14 at a second joint attachment interface 36. Depending on load requirements for this type of structural wheel 10, a third joint attachment interface 48 may also be required. The joint attachment interfaces could be accomplished through any of various joining processes. For example, these interfaces could be made by using MIG/Plasma welding, laser welding, hybrid-laser welding, MIG/MAG welding, mechanical attachments (rivets, fasteners, etc.), or chemical attachments (adhesive, for example).
As discussed above, each second arm end 30 also includes a fastener aperture 38 to receive a fastener. As shown in Figure 2, when all of the structural arms 16 are attached to the center disc portion 14, the fastener apertures 38 define a bolted joint interface 40 for securement to a rotating wheel structure. A shown in Figure 3, each structural arm 16 includes a flange portion 42 at the first arm end 28 that extends outwardly from the arm body 26 in a direction transverse to the radial direction. The flange portion 42 defines an abutment surface that contacts the inner peripheral surface 32 of the rim 12. The first weld attachment interface 34 is formed at this flange portion 42.
Each structural arm 16 also includes a flange portion 50 that extends about a periphery of the second arm end 30. The flange portion 50 extends outwardly from the arm body 26 in a direction transverse to the radial direction. In one example, the flange portion 50 is formed about a significant portion of the arm body 26 to provide increased strength. The flange portion 50 at the second arm ends 30 are received in abutting engagement with respective curved recesses 24. The second weld attachment interface 36 is formed at these flange portions 50. As shown in Figure 4, the second arm ends 30 are rounded such that they correspond generally in shape to the contour of the curved recesses 24. The first arm ends 28 also present a curved surface that corresponds generally in contour to the inner peripheral surface 32 of the rim 12.
Additional holes will be introduced on the arms 16 to provide a concentric position of the arms 16 in relation to the center disc portion 14 and the rim 12. The arms 16 may also include features to clamp wheel covers or different design enhancement attachments to the wheel 10. Some examples of holes 80 in the arms 16 are shown in Figures 11 A-11C.
Figure 5 shows a cross-sectional view of the rim 12, center disc portion 14, and structural arms 16. Figures 6 and 7 show a feature 60 that comprises a valve hole.
In order to provide a desired aesthetic appearance, at least a portion of the vehicle wheel 10 is overmolded with a plastic or composite material. In the example shown in Figures 8A-8B, outer surfaces 70 of the cen- ter disc portion 14 and structural arms 16 are covered with an overmold layer of material 72 to provide a desired appearance. It should be understood that additional surfaces of these structures could also include such a layer, or on- Iy portions of these surfaces may include a layer of material. Figure 8A shows and example where a plastic material is used and Figure 8B shows an example where a composite material is used.
A center portion of the wheel 10, formed by the structural arms 16 and the center disc portion 14 can be attached to the rim 12 in any of various mounting positions. Figures 12A-12C show examples of different mounting positions. Figure 12A shows a bead-seat attachment 90a near an outer edge 92a of the rim 12 with a drop-well 94a immediately adjacent the arms 16. Figure 12B shows a bead-seat attachment 90b near the outer edge 92b with an inverted drop-well 94b that is spaced away from the arms 16. Figure 12C shows a bead-seat attachment 90c at the drop-well 94b, i.e. Figure 12 C shows a drop-center attachment configuration.
A wheel comprised of a combination of structural arms and a center disc portion as described above provides a low cost and very robust wheel. Further, when a desired aesthetic appearance is required, this type of wheel structure in combination with overmolded plastic or composite material provides a complex wheel design that is easily provided made without adversely affecting weight or cost.