Abstract:
A method for producing a vehicle wheel comprises the steps of: (a) providing a wheel including an outboard face; (b) providing a wheel cover including an inner surface; (c) providing an external surface feature on at least one of the outboard face of the wheel and the inner surface of the cover; (d) positioning the wheel and the cover relative to one another to form a first gap between at least selected portions of the wheel outboard face of the cover inner surface and to form at least a second gap in the area of the external surface feature between adjacent surfaces of the wheel and the wheel cover, the first gap to the second gap defining an indirect flow path; and (e) securing the cover to the wheel by using an expandable foam adhesive material, wherein the adhesive material initially fills selected portions of the first gap and then follows the indirect flow path to then flow into the second gap whereby the adhesive material cures and stops expanding before completely filling the second gap.

Description:
BACKGROUND OF THE INVENTION 
     This invention relates in general to vehicle wheels and, in particular, to an improved vehicle wheel cover-retention system and method for producing the same. 
     Automotive wheels serve two main purposes: the wheels support the vehicle and associated tires and the wheels provide an aesthetically pleasing appearance. Current technology often involves tradeoffs between those two goals. Wheels are typically constructed of metal or metal alloys, although alternative materials, such as composites, are envisioned. The aesthetic appearance of such a wheel is limited by manufacturing methods to form a given styled surface. Additionally, such a wheel will often have excess material (and weight) added to form the styled surface. 
     Wheel clads or covers are used to simulate a styled wheel surface while utilizing a structural wheel underneath to support any loads imparted on the wheel. The wheel cover is typically made of a plastic or thin metal material that is more easily formable into pleasing aesthetic shapes. The cover is then attached to the wheel by mechanical means, whether fasteners, adhesives or locking features formed into the cover or the wheel. The cover can also receive a special surface coating to enhance its appearance, such as a bright paint or chrome plating. It is desirable that the cover is not easily discernible as separate from the wheel. It is also desirable to eliminate evidence of a cover being used such as mating lines, a hollow sound when tapped, yielding to moderate pressure, preventing the entry of foreign matter between the parts and visible wheel surfaces behind the cover. To this end, a suitable adhesive foam material is often used to deaden the hollow sound when tapped, fill the space between the wheel and cover to prevent entry of foreign matter and support the cover when pressure is applied to the cover. 
     It can be very difficult to use adhesives to join the cover and the wheel in a high volume manufacturing environment because the adhesive requires sufficient time for a chemical reaction to occur and expand (in the case of foam adhesives), attain handling strength and subsequently full strength. A fast curing adhesive will allow faster throughput but also cures quickly in the mixing equipment and requires more maintenance. Conversely, a slow curing adhesive possesses a longer open time before clogging inside the dispensing equipment but requires more work-in-process inventory and related resources, such as, floor space, cure ovens, material handling equipment and tooling. 
     Furthermore, when using an expanding foam adhesive material, the cover and wheel assembly can be encapsulated inside a masking mold to contain the expanding foam adhesive material. However, there often exists a path internal to the cover and wheel assembly through which it is undesirable to allow the expanding foam adhesive material to enter. It is not feasible to mask off certain areas when the cover and wheel are assembled. 
     SUMMARY OF THE INVENTION 
     This invention relates to a vehicle wheel cover retention system and method for producing such a vehicle wheel. 
     According to one embodiment, the method for producing the vehicle wheel comprising the steps of: (a) providing a vehicle wheel defining an axis and formed from a suitable material and including a wheel rim and a wheel disc, the vehicle wheel including an outboard face; (b) providing a wheel cover formed from a suitable material and including an inner surface and an outer surface; (c) providing an external surface feature on at least one of the outboard face of the vehicle wheel and the inner surface of the wheel cover; (d) positioning the vehicle wheel and the wheel cover relative to one another to form a first gap between at least selected portions of the outboard face of the vehicle wheel and the inner surface of the wheel cover and to form at least a second gap in the area of the external surface feature between adjacent surfaces of the vehicle wheel and the wheel cover, the first gap to the second gap defining an indirect flow path; and (e) securing the wheel cover to the vehicle wheel by using an expandable foam adhesive material, wherein the expandable foam adhesive material initially fills selected portions of the first gap and then follows the indirect flow path to then flow into the second gap whereby the expanding adhesive foam material cures and stops expanding before completely filling the second gap. 
     According to another embodiment, the method for producing the vehicle wheel comprising the steps of: (a) providing a vehicle wheel defining an axis and formed from a suitable material and including a wheel rim and a wheel disc, the vehicle wheel including an outboard face; (b) providing a wheel cover formed from a suitable material and including an inner surface and an outer surface; (c) providing an inboard external surface feature on at least one of the outboard face of the vehicle wheel and the inner surface of the wheel cover; (d) providing an outboard external surface feature on the inner surface of the wheel cover; (e) positioning the vehicle wheel and the wheel cover relative to one another to form a first gap between at least selected portions of the outboard face of the vehicle wheel and the inner surface of the wheel cover and to form at least a second gap in the area of the inboard external surface feature between adjacent surfaces of the vehicle wheel and the wheel cover and a third gap in the area of the outboard external surface between adjacent surfaces of the vehicle wheel and the wheel cover, the first gap to the second gap defining a first indirect flow path and the first gap to the third gap defining a second indirect flow path; and (f) securing the wheel cover to the vehicle wheel by using an expandable foam adhesive material, wherein the expandable foam adhesive material initially fills selected portions of the first gap and then follows the first indirect flow path to then flow into the second gap, whereby the expanding adhesive foam material cures and stops expanding before completely filling the second gap, and at the same time, then follows the second indirect flow path to then flow into the third gap, whereby the expanding adhesive foam material cures and stops expanding before completely filling the third gap. 
     According to one embodiment, the vehicle wheel cover retention system comprises: a wheel defining an axis and formed from a suitable material and including a wheel rim and a wheel disc, the wheel including an outboard face; a wheel cover formed from a suitable material and including an inner surface and an outer surface; and an expandable foam adhesive disposed between at least a portion of the outboard face of the wheel and the inner surface of the wheel cover; wherein the vehicle wheel and the wheel cover include a first gap between at least selected portions of the outboard face of the vehicle wheel and the inner surface of the wheel cover and at least a second gap in the area of the external surface feature between adjacent surfaces of the vehicle wheel and the wheel cover, the first gap to the second gap defining an indirect flow path such that the expandable foam adhesive material initially fills selected portions of the first gap and then follows the indirect flow path to then flow into the second gap whereby the expanding adhesive foam material cures and stops expanding before completely filling second gap. 
     Other advantages of this invention will become apparent to those skilled in the art from the following detailed description of the invention, when read in light of the accompanying drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a view of a portion of a vehicle wheel including a first embodiment of a vehicle wheel cover retention system, the vehicle wheel being shown without any adhesive material present. 
         FIG. 2  is a view similar to that shown in  FIG. 1 , but showing the adhesive material present. 
         FIG. 3  is an enlarged view of a portion of the vehicle wheel illustrated in  FIG. 2 . 
         FIG. 4  is a view similar to  FIG. 2  showing an alternate embodiment. 
         FIG. 5  is a view similar to  FIG. 2  showing another alternate embodiment. 
         FIG. 6  is an enlarged view of a portion of the vehicle wheel illustrated in  FIG. 1 , the vehicle wheel being shown without any adhesive present. 
         FIG. 7  is an enlarged view of portion of the vehicle wheel illustrated in  FIG. 2 , with the vehicle wheel being removed. 
         FIG. 8  is a block diagram illustrating a sequence of steps for producing the embodiments of the vehicle wheel. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Referring now to the drawings, there is illustrated in  FIGS. 1 and 2  a view of a portion of a vehicle wheel, indicated generally at  10 , including a first embodiment of a vehicle wheel cover retention system, indicated generally at  12 . As shown therein, the vehicle wheel  10  defines an axis X and may be of any suitable type of material or materials, such as for example, steel, aluminum and alloys thereof, and may be of any suitable type of wheel construction, such as for example, a “full face” type of wheel, such as shown in FIG. 5A of U.S. Pat. No. 5,533,261 to Kemmerer, a “bead seat attached” wheel such as shown in FIG. 4 of U.S. Pat. No. 5,188,429 to Heck et al., a “well attached” wheel such as shown in FIG. 3 of U.S. Pat. No. 5,188,429 to Heck et al., a “bimetal” wheel construction including an aluminum disc and a steel rim such as shown in U.S. Pat. No. 5,421,642 to Wei et al., a “modular wheel” construction such as shown in U.S. Pat. No. 5,360,261 to Archibald et al., a cast aluminum wheel such as shown in U.S. Pat. No. 5,340,418 to Wei, or a euroflange type of wheel such as shown in U.S. Pat. No. 5,564,792 to Archibald, the disclosures of all of these patents incorporated by reference in entirety herein. 
     In the illustrated embodiment the vehicle wheel  10  is a one-piece full cast aluminum wheel and includes a wheel rim, indicated generally at  14 , and a wheel disc, indicated generally at  16 . The wheel rim  14  includes an inboard tire bead seat retaining flange  14 A, and inboard tire bead seat  14 B, a generally axially extending well  14 C, and outboard tire bead seat  14 D, and an outboard tire bead seat retaining flange  14 E. Alternatively, the construction, material and/or make-up of the wheel rim  14  may be other than illustrated if so desired. 
     The wheel disc  16  includes a generally centrally located inner wheel mounting surface or portion  18 , an outer annular portion  20 , and defines an outer surface or outboard face  22 . The inner mounting surface  18  of the wheel disc  16  is provided with a center hub hole  18 A and a plurality of lug bolt mounting holes  18 B spaced circumferentially around the center hub hole  18 A (one of such lug bolt mounting holes  18 B illustrated in  FIGS. 1 and 2 ). The lug bolt receiving holes  18 B are adapted to receive lug bolts (not shown) and nuts (not shown) for securing the vehicle wheel  10  on an axle (not shown) of a vehicle. 
     In the illustrated embodiment, the wheel cover  30  is formed from plastic and is a one-piece wheel cover and may have at least an outer surface which is painted, chrome-plated or otherwise adorned or decorated as desired. Alternatively, the wheel cover  30  may be formed from other materials, such as metal and/or may be a multi-piece wheel cover formed of like or unlike materials if so desired. The wheel cover  30  may have an inner surface which closely conforms to the outboard face of the wheel, may have an inner surface which is spaced from the outboard face of the wheel to impart the styling to the wheel, or may have a combination of both an inner surface which conforms and an inner surface which is spaced apart from the outboard face of the wheel. 
     As will be discussed below, the wheel cover  30  is provided having internal baffles or ribs which are operative to create a serpentine or indirect path that will restrict or reduce the entry of an expanding foam adhesive material  34  into certain areas between the vehicle wheel  10  and the wheel cover  16 , such as a wheel hub area, indicated generally at  36 , adjacent to lug bolt mounting holes  18 A. The expanding foam adhesive material  34  generates some internal pressure (about 10 psi gage) and can pass through a gap that is relatively small (about three (3) mm tall or greater), rather easily. At very small gap heights (roughly about 0.5 mm), the expanding foam adhesive material  34  will encounter significant resistance trying to penetrate the gap. 
     During the time that the foam adhesive material  34  is expanding and curing, some foam adhesive material  34  will progress through the indirect path but at a slow rate such that the foam adhesive material  34  will stop expanding in the indirect path or shortly after exiting it. By creating an indirect path for the expanding foam adhesive material  34 , the foam material&#39;s fill path can be controlled without having a perfect seal or interface between the wheel cover  30  and the vehicle wheel  10 . In the illustrated embodiment, the indirect path is preferably created by forming or molding the baffles or ribs into the wheel cover  30  and by controlling an outer profile or surface on the outboard face  22  of the vehicle wheel  10  that the wheel cover  30  is to cover. Some possible embodiments of the indirect path are as follows: 
     For example, as shown in the embodiment shown in  FIG. 3 , the inner mounting surface  18  in the wheel hub area  36  of the vehicle wheel  10  is provided with a revolved or stepped annular ledge or shoulder, indicated generally at  38 , and the wheel cover  30  is provided with a baffle or rib  40 . The shoulder  38  is provided at that portion wherein the wheel outboard face  22  goes from high-to-low or low-to-high position. In this embodiment, the rib  40  is preferably a continuous circumferentially extending annular rib and extends generally axially inwardly from an inner surface  30 A of the wheel cover  30 . As shown in the upper half of  FIGS. 1 and 2 , the wheel cover  30  may extend inwardly relative to the rib  40  or as shown in the lower half of  FIGS. 1 and 2 , the wheel cover  30  may end adjacent the rib  40 . Also, the vehicle wheel  10  may have a center cap (not shown) which is adapted to cover the wheel hub area  36  of the wheel  10 . The center cap may be releasably attached to the vehicle wheel  10  and/or the wheel cover  30  by suitable means. 
     As shown in the illustrated embodiment, the rib  40  includes a generally axially extending outer surface  40 A and a remote end  40 B. Preferably, the outer surface  40 A is positioned adjacent or near a generally axially extending side wall surface  38 A of the shoulder  38  and the remote end  40 B is spaced apart from contact with a generally radially extending surface  38 B of the shoulder  38  to thereby produce an indirect path, as generally indicated by arrow  42  in  FIG. 3 . 
     In this embodiment the indirect path  42  is generally Z-shaped and is defined by the outboard face  22  of the wheel  10  and the surfaces  38 A and  38 B of the shoulder  38  of the wheel  10  in conjunction with the adjacent surfaces of the wheel cover  30 , namely the inner surface  30 A and the outer surface  40 A and the remote end  40 B of the rib  40 . Thus, it can be seen that the indirect path  42  in this embodiment preferably extends in at least three directions for a purpose to be discussed below. Namely, the indirect path  42  extends first in a generally radially inwardly extending direction D 1  (i.e., generally along surface  22 ), second in a generally axially inwardly extending direction D 2  (i.e., generally along surface  38 A), and lastly in a generally radially inwardly extending direction D 3  (i.e., generally along surface  38 B). 
     In this embodiment, as a result of the indirect path  42 , as the foam adhesive material  34  is expanding, any foam adhesive material  34  that flows inwardly between the surfaces  22  and  30  is rerouted into a circumferentially extending annular space or gap, indicated generally at  46 , which is defined between the surfaces  38 A and  40 A because this space of the annular gap  46  remains at zero gage pressure until it is filled with any of expanding foam adhesive material  34 . While the annular space  46  between the surfaces  38 A and  40 A is filling, the foam adhesive material  34  is curing. 
     In this embodiment, by creating an appropriate or preselected volume for the annular space  46  between the surfaces  38   a  and  40 A, any of the foam adhesive material  34  that enters the annular gap  46  will preferably cure and stop expanding before completely filling the gap  46 . Therefore, there is no impetus to force the foam adhesive material  34  past the gap  46 . Thus, this feature of the illustrated embodiment will preferably eliminate any secondary operations, and their related costs, such as having to create a seal or use a gasket in this area of the vehicle wheel during assembly of the wheel cover  30  to the vehicle wheel  10 . Alternatively, the shape, construction, arrangement, number, orientation and/or make-up of the shoulder  38  of the wheel  10  and/or the rib  40  of the cover  30  may be other than illustrated, in order to produce a desired serpentine path, if so desired. Additionally, in the illustrated embodiment, another gap or space, indicated generally at  48 , is provided between the surfaces  38 B and  40 B. Preferably, the foam adhesive material  34  is captured and retained in the gap  46 ; however, in some instances, the gap  48  may also contain some of the foam adhesive material  34 . 
     For example, as shown in the embodiment illustrated in  FIG. 4  and using like reference numbers to indicate like parts, there is illustrated an alternate embodiment of the vehicle wheel  10 . As shown therein, in this embodiment a narrow generally U-shaped annular trough or recess, indicated generally at  44 , is provided in the inner mounting surface  18  in the wheel hub area  36  of the vehicle wheel  10 . The recess  44  includes a generally extending side wall  44 A and a generally radially extending curved or radiused surface  44 B. Preferably, as shown in the illustrated embodiment, the rib  40  of the wheel cover  30  is positioned adjacent to or near to the side wall surface  44 A of the recess  44  thereby producing an indirect path. Also, as shown in the illustrated embodiment, the remote end  40 A of the rib  40  is preferably spaced apart from contact with the surface  44 B of the recess  44 . As can be seen in this embodiment, in addition to the gap between the outboard face  22  and the inner surface  30 A of the wheel cover  30 , three additional gaps or spaces, indicated generally at G 1 , G 2  and G 3 , are provided between the adjacent surfaces of the recess  44  and the rib  40 . 
     For example, as shown in the embodiment illustrated in  FIG. 5  and using like reference numbers to indicate like parts, there is illustrated another alternate embodiment of the vehicle wheel  10 . As shown therein, in this embodiment, a generally narrow annular protruding lug  50  is provided on the vehicle wheel  14 . The lug  50  is adapted to be situated or disposed between a pair of spaced apart annular ribs  52 A and  52 B provided on the wheel cover  30  thereby producing an indirect path, the path being a generally inverted U-shaped path. As can be seen in this embodiment, in addition to the gap between the outboard face  22  and the inner surface  30 A of the wheel cover  30 , at least three additional gaps or spaces, indicated generally at G 10 , G 20  and G 30 , are provided between the adjacent surfaces of the lug  50  and the ribs  52 A and  52 B. 
     As best shown in  FIG. 6 , a different situation exists at the outboard face  22 A of vehicle wheel  10  in the area of the outboard tire bead seat retaining flange  14 E. In this area, the wheel cover  30  will preferably contact the outboard face  22  of the vehicle wheel  10  directly as this is a datum or reference point for both of the parts. During the assembly process, the parts are temporarily clamped or held together by suitable means, while the foam adhesive material  34  is expanding under its own internal pressure counteracting the clamping force. It is desirable to prevent the expanding foam adhesive material  34  from squeezing through the seam or interface produced in this area. Thus, according to the illustrated embodiment shown in  FIGS. 6 and 7 , there is preferably provided on the wheel cover  30  two molded generally concentric, circumferentially extending spaced apart annular ribs, namely an inner rib  56 A and an outer rib  56 B. 
     In the illustrated embodiment, the two ribs  56 A and  56 B on the wheel cover  30  are generally identical to one another are preferably operative to mate or contact the wheel outboard face  22  which is located generally normal to the ribs  56 A and  56 B. As a result, as the foam adhesive material  34  is expanding, any foam adhesive material  34  that squeezes or flows past the inner rib  56 A (such flow indicated by arrows  58  in  FIG. 7 ), is then rerouted circumferentially in a circumferentially extending annular space or gap, indicated generally at  60 , which is defined between the inner rib  56 A and outer rib  56 B because this space of the annular gap  60  remains at zero gage pressure until it is filled with any of expanding foam adhesive material  34 . While the annular space  60  between the inner rib  56 A and the outer rib  56 B is filling, the foam adhesive material  34  is curing. 
     In this embodiment, by creating an appropriate or preselected volume for the annular space  60  between the ribs  56 A and  56 B, any of the foam adhesive material  34  that enters the annular gap  60  will cure and stop expanding before completely filling the gap  60 . Therefore, there is no impetus to force the foam adhesive material  34  past the outer circumferential rib  56 B. Thus, this feature of the illustrated embodiment will preferably eliminate any secondary operations, and their related costs, such as having to create a seal or use a gasket in this area of the vehicle wheel during assembly of the wheel cover  30  to the vehicle wheel  10 . Alternatively, the shape, construction, arrangement, number, orientation and/or make-up of the ribs  56 A and  56 B of the cover  30  may be other than illustrated, in order to produce a desired serpentine path, if so desired. For example, the ribs  56 A and  56 B may be of different shapes and/or of different heights if so desired. 
     A method for producing a vehicle wheel  10  may be as shown in  FIG. 8 . First, in step  70 , a vehicle wheel, such as the vehicle wheel  70  is provided. Next, in step  72 , a wheel cover, such as the wheel cover  30  is provided. In step  74 , the vehicle wheel  10  and the wheel cover  30  are positioned relative to one another. Following this, in step  76 , the wheel cover  30  is secured to the vehicle wheel  10  using a suitable adhesive, such as for example, the expanding foam adhesive material  34 , to thereby produce the finished wheel. 
     As discussed above, the particular shape, construction, arrangement, number, orientation and/or make-up of the shoulder  38 , recess  44 , lug  50 , and/or ribs  40 ,  56 A and  56 B of the wheel  10  may be other than illustrated, so as to produce a desired serpentine path. Also, in addition to the use of the expanding foam adhesive material  34 , other types of adhesive materials, for example, non-expanding foam adhesive materials, may be used in conjunction with the expanding foam adhesive material  34  or in place thereof. 
     Also, the expanding foam adhesive material  34  and/or the non-expanding foam adhesive material can be selectively applied in a pre-assembly pattern so as to result in a full surface post-assembly pattern (shown in upper half of  FIG. 2 ), or in a non-full surface post-assembly pattern (shown in the lower half of  FIG. 2 ), i.e., a post-assembly pattern which has one or more voids or gaps  24  therein. Suitable types of non-expanding foam adhesives may include but are not limited to the use of one or a combination of more than one of adhesives selected from the group consisting of silicone, two-part epoxy, urethane, double-sided tape, expanding foam, and the like. Also, in addition to the expanding foam adhesive material  34 , the other mechanical means, such as for example, snap tabs and fasteners, which may be part of the wheel cover  30  or separate components, may be used to assist in securing the wheel cover  30  to the vehicle wheel  10 . 
     Also, it will be understood that other geometric shapes for the shoulder  38 , recess  44 , lug  50  and/or ribs  40 ,  56 A and  56 B are envisioned and that the illustrated embodiments are not limited to the specific shapes disclosed above. One skilled in the art could design other appropriate shapes to produce a desired serpentine path based on the basic shape of the associated vehicle wheel and wheel cover while considering structural performance, manufacturing and assembly and aesthetic features of the parts. 
     In accordance with the provisions of the patent statutes, the principle and mode of operation of this invention have been described and illustrated in its various embodiments. However, it must be understood that the invention may be practiced otherwise than as specifically explained and illustrated without departing from the scope or spirit of the attached claims.