Abstract:
This invention relates to a method and apparatus for producing a wheel cover and a vehicle wheel including such a wheel cover. The method for producing the vehicle wheel cover comprises the steps of: (a) providing a tooling fixture including at least a first tooling member and a second tooling member; (b) providing a wheel cover having at least a preformed outer end; (c) positioning the wheel cover onto the tooling fixture wherein the wheel cover is supported on the first tooling member and spaced apart from the second tooling member; (d) actuating the tooling fixture whereby the second tooling member is operative to engage and reshape the outer end of the wheel cover to produce a desired outer end shape; and (e) removing the wheel cover from the tooling fixture.

Description:
BACKGROUND OF THE INVENTION  
       [0001]     This invention relates in general to vehicle wheels and, in particular, to a method and apparatus for producing a wheel cover and a vehicle wheel including such a wheel cover.  
         [0002]     Full or partial vehicle wheel covers of the removable type are well known and have been used for many years to enhance the styling of conventional, stamped wheel discs. Also, it is known to permanently secure a full or a partial wheel cover to a vehicle wheel using a suitable type of an adhesive.  
         [0003]     One example of a vehicle wheel construction wherein a wheel cover is permanently secured to a wheel by an adhesive is disclosed in U.S. Pat. No. 5,595,423 to Heck et al. In the Heck et al. patent, the wheel cover includes an outer end which is disposed in a groove formed in an outer peripheral end of the outboard tire bead seat retaining flange such that the cover covers the entire portion of the outer peripheral end of the outboard tire bead seat retaining flange.  
       SUMMARY OF THE INVENTION  
       [0004]     This invention relates to a method and apparatus for producing a wheel cover and a vehicle wheel including such a wheel cover. The method for producing the vehicle wheel cover comprises the steps of: (a) providing a tooling fixture including at least a first tooling member and a second tooling member; (b) providing a wheel cover having at least a preformed outer end; (c) positioning the wheel cover onto the tooling fixture wherein the wheel cover is supported on the first tooling member and spaced apart from the second tooling member; (d) actuating the tooling fixture whereby the second tooling member is operative to engage and reshape the outer end of the wheel cover to produce a desired outer end shape; and (e) removing the wheel cover from the tooling fixture. The apparatus for producing the vehicle wheel cover comprises: a tooling fixture including a first tooling member and a second tooling member, at least the second tooling member being moveable relative to the first tooling member, the first tooling member having a groove formed therein which defines a surface profile and the second tooling member including a portion having a surface profile which is generally complimentary to the surface profile of the groove.  
         [0005]     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  
       [0006]      FIG. 1  is a sectional view of a prior art vehicle wheel.  
         [0007]      FIG. 2  is a sectional view of a portion of the vehicle wheel illustrated in  FIG. 1 , including a wheel cover produced in accordance with the present invention.  
         [0008]      FIG. 3  is another view of the wheel cover illustrated in  FIG. 2 .  
         [0009]      FIG. 4  is a block diagram illustrating a sequence of steps for producing the wheel cover in accordance with the present invention.  
         [0010]      FIG. 5  is a view of a portion of tooling for use in producing the wheel cover illustrated in  FIGS. 2 and 3 , with only the tooling being shown.  
         [0011]      FIG. 6  is another view of the tooling, showing the initial position of the tooling and a portion of a wheel cover preform.  
         [0012]      FIG. 7  is another view of the tooling, showing the end working position of the tooling and a portion of the finished wheel cover shown in  FIGS. 2 and 3 .  
         [0013]      FIG. 8  is a view of a portion of a second embodiment of a vehicle wheel including a wheel cover produced in accordance with the present invention. 
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0014]     Referring now to the drawings, there is illustrated in prior art  FIG. 1 a  sectional view of a vehicle wheel, indicated generally at  10 , which is adapted to have installed thereon a wheel cover produced in accordance with the present invention. The prior art vehicle wheel  10  can be of any suitable type of material or materials, such as for example, steel, aluminum and alloys thereof, and can 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 euro-flange 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.  
         [0015]     As shown in the embodiment illustrated in prior art  FIG. 1 , the vehicle wheel  10  is a full face fabricated vehicle wheel and includes a “partial” wheel rim, indicated generally at  20 , and a full face wheel disc, indicated generally at  40 , which are constructed and joined together by suitable means, such as for example by welding. The prior art full face fabricated vehicle wheel  10  defines a horizontal or longitudinal vehicle wheel axis X.  
         [0016]     The wheel rim  20  is a fabricated wheel rim and is formed from a suitable material, such as for example, steel, aluminum or alloys thereof, magnesium, or titanium. The wheel rim  20  includes an inboard tire bead seat retaining flange  22 , an inboard tire bead seat  24 , a generally axially extending well  26 , and an outboard tire bead seat  28 . The outboard tire bead seat  28  terminates at an outermost end  28 A. In this embodiment, the outermost end  28 A is turned radially inwardly and a weld  30  is provided to join the wheel rim  20  and the wheel disc  40  together.  
         [0017]     The wheel disc  40  is a fabricated wheel disc and is formed from a suitable material, such as for example, steel, aluminum or alloys thereof, magnesium, or titanium. The wheel disc  40  includes a generally centrally located wheel mounting surface or portion  42  and an outer annular portion  44 . The outer annular portion  44  defines an outboard tire bead seat retaining flange  46  of the vehicle wheel  10 .  
         [0018]     The wheel mounting surface  42  of the wheel disc  40  is provided with a centrally located pilot aperture  42 A and a plurality of lug bolt receiving holes  42 B circumferentially spaced around the pilot aperture  42 A (only one of such lug bolt receiving holes  42 B illustrated in prior art  FIG. 1 ). The lug bolt receiving holes  42 B receive lug bolts (not shown) and nuts (not shown) for securing the vehicle wheel  10  on an axle (not shown) of a vehicle. The wheel disc  40  may also include one or more vent windows  48  formed therein (only one of such windows  48  illustrated in prior art  FIG. 1 ).  
         [0019]     As shown in the embodiment of prior art  FIG. 1 , the outboard tire bead seat retaining flange  46  of the disc  40  includes a generally smooth and rounded outer peripheral end  50 . The outer end  50  is provided with a circumferential, radially inwardly facing groove or recess  52  formed in an inner surface  46 A thereof. In the embodiment illustrated, the groove  52  has a generally curved or rounded shape. The peripheral end  50  and the groove  52  are preferably formed by a machining operation to predetermined specifications. However, the peripheral end  50  and/or the groove  52  can be formed by other methods. For example, the peripheral end  50  and/or the groove  52  can be formed by a stamping operation or a spinning operation. Preferably, the groove  52  is formed in such a manner that when the wheel cover is installed on the wheel  10  the wheel cover is preferably completely recessed within the groove  52 .  
         [0020]     Referring now to  FIG. 4 , there is illustrated a block diagram illustrating a sequence of steps for producing a wheel cover, indicated generally at  60  in  FIGS. 2 and 3 , in accordance with the present invention. The wheel cover  60  of the present invention can be used in connection with the vehicle wheel  10  illustrated in prior art  FIG. 1  or in connection with any other desired type of vehicle wheel.  
         [0021]     Initially, in step  100 , a tooling fixture or apparatus  110 , partially shown in  FIG. 5 , in accordance with this invention is provided to be used to produce the wheel cover  60 . As shown in  FIG. 5 , the tooling fixture  110  includes a first tooling member or anvil  112 , a second tooling member or cam slide  116  and a third tooling member or upper pad  114 . The first tooling member  112  can be a one-piece tooling member or can be made up of two or more tooling members. In the illustrated embodiment, the first tooling member  112  is a generally annular one-piece tooling member and includes an outer end  120  having a generally rounded first surface  122 , a generally flat second surface  124 , a generally angled third or intermediate surface  126 , and a generally flat fourth surface  128 . The outer end  120  further includes an annular groove or recess  130  formed therein at the transition of the second surface  124  to the third surface  126 . The recess  130  is preferably in the form of a radius and defines an inner diameter D 1  of the first member  112 . Also, the fourth surface  128  is preferably spaced apart from an outer endmost surface  122 A of the first surface  122  by an axial distance X 1 , for a purpose to be discussed below. In the illustrated embodiment, the second surface  124  is generally perpendicular to the fourth surface  128  and the third surface  126  is located at an angle, which is shown in the illustrated embodiment as being about 55 degrees, with respect to the fourth surface  128 . Alternatively, the profile or construction of the outer end  120  of the first tooling member  112  can be other than illustrated if so desired.  
         [0022]     The third tooling member  114  can be a one-piece tooling member or can be made up of two or more tooling members. In the illustrated embodiment, the third tooling member  114  is a one-piece tooling member and is preferably moveable in the direction of arrow  132  between a retracted non-working position (shown in  FIGS. 5 and 6 ), and an extending working position (shown in  FIG. 7 ). In the illustrated embodiment, the third tooling member  114  includes an end  140  provided with a first or inner surface  142  and a second or outer surface  144 . The first surface  142  is slightly curved or rounded and the second surface  144  is curved or rounded. As can be seen in the illustrated embodiment, portions of the first surface  142  and the second surface  144  of the third tooling member  114  are generally complimentary to portions of the rounded surface  122  of the first tooling member  112 . Alternatively, the profile or construction of the end  140  of the third tooling member  114  can be other than illustrated if so desired  
         [0023]     The second tooling member  116  is comprised of at least two or more tooling members, such as for example four, nine or twelve tooling members, and is preferably moveable in the direction of arrow  148  between a retracted non-working position (shown in  FIGS. 5 and 6 ), and an extending working position (shown in  FIG. 7 ). In the illustrated embodiment, the second tooling member  116  includes an end  150  provided with a first surface  152  and a second surface  154 . The first surface  152  is non-flat or rounded and the second surface  154  is generally flat and angled with respect to the first surface  152 . Preferably, as shown in the illustrated embodiment, the curvature or profile of the first surface  152  of the second tooling member  116  is generally complimentary to the curvature or profile of the recess  130  of the first tooling member  112 . Alternatively, the profile or construction of the end  150  of the second tooling member  116  can be other than illustrated if so desired.  
         [0024]     Next, in step  102 , a wheel cover  160  (partially shown in  FIG. 6 ), is provided. The wheel cover  160  can be formed of any suitable material, such as for example, steel, aluminum, and plastic. In the illustrated embodiment, the wheel cover  160  is formed from steel, preferably stainless steel. In the illustrated embodiment, the wheel cover  160  is preferably a preformed wheel cover having a desired final shape or configuration throughout its entire body except for in the area of an outer end  162  thereof. In particular, the wheel cover  160  preferably includes a plurality of openings (not shown) which can correspond to the windows  48  formed in the disc  40 . The wheel cover openings preferably extend slightly past edges of the windows  48  to effectively overlap the edges of the windows  48 . Also, the body of the wheel cover  160  can either extend inwardly short of the lug bolt openings  42 B or can extend past the lug bolt openings  42  depending upon the particular wheel design, such as for example, if a center cap (not shown) is used.  
         [0025]     As shown in the embodiment illustrated in  FIG. 6 , the outer end  162  of the wheel cover  160  is preformed in a generally U-shaped outer end and includes a first or inner portion  164 , a second intermediate portion  166 , and a third or outer portion  168 . In the illustrated embodiment, the first portion  164  and the third portion  168  extend generally parallel with respect to each other and include inner surfaces  164 A and  168 A, respectively, which are spaced apart from each other by a distance Y 1 . The second portion  164  is generally rounded. Also, an end surface  168 B of the third portion  168  is preferably spaced apart from an inner surface  166 A of the second portion  166  by an axial distance X 2 . Preferably, the axial distance X 2  is generally equal to the axial distance X 1 , for a purpose to be discussed below.  
         [0026]     Next, in step  104 , the wheel cover  160  is positioned on the tooling fixture  110  as shown in  FIG. 6 . Following this, in step  106 , the tooling fixture  110  is actuated such that the third tooling member  114  and the second tooling member  116  are moved to the extending working positions shown in  FIG. 7 . In particular, during step  106 , the third tooling member  114  is moved in a generally downwardly direction in  FIG. 7  and the second tooling member  116  is moved in a generally leftward direction in  FIG. 7  to thereby form the finished wheel cover  60  having an outer end  62  provided with the shape best in  FIGS. 2 and 3 . Preferably, the second tooling member  116  does not engage and shape the outer end of the wheel cover until the third tooling member  114  is in the position shown in  FIG. 7 .  
         [0027]     As can be seen in  FIG. 7 , in this embodiment and in this position, a portion of the second portion  166  of the wheel cover  160  is captured or engaged between a portion of the outer end  120  of the first tooling member  112  and a portion of the outer end  140  of the third tooling member  114 .  
         [0028]     Also, as can be seen in  FIG. 7 , during step  106 , the second tooling member  116  in this embodiment is preferably in contact with and guided by the third surface  128  of the first tooling member  112  as it moves to the extended working position. Also, the rounded surface  152  of the second tooling member  116  initially engages the outer portion  168  of the wheel cover  160  and as it is moved is operative to reshape and form the outer end  62  to a desired final shape or configuration. As can be understood, during step  106 , the angled surface  126  of the first tooling member  112  is operative to provide a ramp or slope for the material to move against as the material is reshaped by the second tooling member  116 . As discussed above, since the groove  130  of the first tooling member  112  and the surface  152  of the second tooling member  116  have complimentary profiles, the material of the wheel cover is reshaped to resemble such profiles. As a result, the shape of the outer end  62  of the wheel cover  60  can be repeatedly and reliably formed to a preselected shape having predetermined tolerances.  
         [0029]     Further, as shown in the embodiment of  FIG. 7 , since the distances X 1  and X 2  are preferably equal to one another, the end surface  168 B of the outer portion  168  of the wheel cover  160  preferably engages the third surface  128  of the first tooling member  112  so as to be supported thereagainst. However, it is to be understood that due to one or more factors, such as manufacturing tolerances and the particular material of the wheel cover  160 , the actual seating or positioning of the wheel cover  160  on the tooling fixture  110  can be other than illustrated in  FIGS. 6 and 7 . Also, the direction of the movement of one or both of the tooling members  114  and  116  can be other than illustrated if so desired depending upon the particular orientation of the wheel cover  160  and/or the particular design of the tooling fixture  110 . Further, the particular tooling member or members which are selectively moveable can be other than illustrated if so desired. Also, the tooling fixture  110  can include any desired number of tooling members. For example, there could be more than or less than the three tooling members shown in the drawings in connection with the illustrated embodiment. For instance, the tooling could include four or more tooling members or could include only two tooling members. In the latter design, the third tooling member  114  and the second tooling member  116  could be formed as a single tooling member or the third tooling member  114  could be eliminated and the tooling fixture  110  only include the tooling members  112  and  116 . In addition, depending upon various factors, such as the type of the material, the thickness of the material and/or the particular shape of the wheel cover, prior to or during step  106 , it may be desirable to preheat or apply heat to the wheel cover  160  and/or the tooling fixture  110  to assist in the forming of the outer end  120  thereof.  
         [0030]     Next, in step  108 , the wheel cover  60  is removed from the tooling fixture  110  and can be further processed, if so desired. Preferably, in this embodiment, the wheel cover  60  is polished and/or otherwise cleaned to remove any tooling marks or other surface imperfections and then is painted, chrome-plated or otherwise adorned to provide a decorative finish on the wheel cover  60  during step  110 . Alternatively, the wheel cover perform  160  provided in step  102  could be already painted, chrome-plated or otherwise adorned so that step  108  would not have to be performed. However, it is preferred to perform step  110  subsequent to step  106 . Also, it is preferred the wheel cover provided in step  102  be preformed as shown in the illustrated embodiment. However, the wheel cover provided in step  102  could not be preformed except for in the area of the outer end portion thereof. In this case, the wheel cover would be formed into a desired final shape in its body portion subsequent to step  106  and preferably prior to step  110 .  
         [0031]     As best shown in  FIG. 3 , the outer end  62  of the wheel cover  60  defines an outer surface  64 , an inner surface  66 , and an outer annular lip  68 . The outer annular lip  68  includes a rounded portion  70  which defines an inner diameter D 2  of the outer end  62  of the wheel cover  60 .  
         [0032]     Following step  110 , the wheel cover  60  is then secured to the vehicle wheel  10  in any suitable manner. As shown in the embodiment illustrated in  FIG. 2 , when the wheel cover  60  is assembled onto the wheel  10  the outer end  62  of the wheel cover  60  is disposed in the groove  52  of the vehicle wheel  10 . Preferably, during assembly, the outer end  62  initially is biased open as the cover  60  is initially assembled onto the outer end  62  and then returns or springs back to its original shape or nearly its original shape so as to be retained in the groove  52  in a mechanical lock-like manner. To accomplish this, the diameter D 1  of the first tooling member  112  is preferably selected so as to be less than an outer diameter D of the groove  52  in the wheel  10  so that in turn, the inner diameter D 2  of the wheel cover  60  will be less than the outer diameter D of the groove  52  prior to assembly of the wheel cover  60  onto the wheel  10 . The particular dimensional relationship of the diameters D, D 1  and D 2  will depend upon many factors, such as for example, the particular material of the wheel cover, the thickness of the wheel cover, the natural spring rate of the material of the wheel cover, the desired amount of force selected to assemble the wheel cover onto the wheel. Preferably, as will be discussed, the mechanical lock of the outer end  62  in the groove  52  is for a time sufficient to enable an adhesive(s) to cure in order to permanently secure the wheel cover  60  to the wheel  10 . A  
         [0033]     As shown in the embodiment illustrated in  FIG. 2 , an adhesive  80  can be disposed between the wheel cover  60  and an outer surface of the wheel disc  40 . The adhesive  80  can be of any suitable type, such as for example, a silicone or urethane adhesive and a foam-in-place or expanding foam filler adhesive, and can be selectively applied in predetermined manner and/or amount so as to completely fill the space between the adjacent surfaces of the cover  60  and the wheel  10  or to only fill selective areas or regions between the adjacent surfaces, if so desired.  
         [0034]     In the illustrated embodiment, the adhesive  80  is a silicone or urethane adhesive selectively deposited so as to be disposed between only selected portions of the wheel cover  60  and the wheel disc  40  following assembly. Alternatively, depending upon the particular type of adhesive or adhesives which are used, the post assembly adhesive pattern between the wheel cover  60  and the wheel  10  can be other than illustrated if so desired.  
         [0035]     Also, in combination with the adhesive(s) or in place thereof, the wheel cover  60  can include mechanical retaining members, such as threaded or non-threaded extensions or posts (not shown), to assist in securing the wheel cover  60  to the wheel  10  for a time sufficient for the adhesive(s) to cure (if adhesive(s) is used) or for securing the wheel cover  60  to the wheel  10 .  
         [0036]     Also, as shown in the embodiment illustrated in  FIG. 8 , a wheel cover  60 ′ having portions which do not closely conform to an outer surface of a wheel disc  40 ′ of a wheel  10 ′ can be produced in accordance with the present invention. The wheel  10 ′ is similar to the wheel  10  and includes a wheel rim  20 ′ joined to the wheel disc  40  by a weld  30 . As shown in the embodiment of  FIG. 8 , a first type of adhesive, such as a non-expandable foam type of adhesive  90 , can be selectively disposed between selected portions of the wheel cover  60 ′ and the wheel  10 ′, and a second type of adhesive, such as an expandable foam or foaming type of adhesive  92 , can be selectively disposed between selected other portions of the wheel cover  60 ′ and the wheel disc  40 ′, following assembly. Also, in this embodiment, the particular shape of an outer end  50 ′ of the wheel  10 ′ and an outer end  162 ′ of the wheel cover  60 ′ are slightly different from that shown in the embodiment best shown in  FIG. 2 .  
         [0037]     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 preferred 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.