Fabricated vehicle wheel and method for producing same

A full face fabricated euroflange vehicle wheel comprises a full face wheel disc defining an axis and formed from a suitable material, the wheel disc having an outer end; and a wheel rim formed from a suitable material and having an outer end joined to the outer end of the wheel disc by at least one weld to produce the fabricated euroflange vehicle wheel; wherein the fabricated euroflange vehicle wheel includes only a generally radially outwardly extending outer end formed by a combination of at least a portion of two of the outer end of the wheel disc the outer end of the wheel rim and the at least one weld.

BACKGROUND OF THE INVENTION

This invention relates in general to vehicle wheels and in particular to an improved full face fabricated euroflange type of vehicle wheel and method for producing the same.

A conventional fabricated vehicle wheel is typically of a two-piece construction and includes an inner disc and an outer “full” rim. The disc can be cast, forged, or fabricated from steel, aluminum, or other alloys, and includes an inner annular wheel mounting portion and an outer annular portion. The wheel mounting portion defines an inboard mounting surface and includes a center pilot or hub hole, and a plurality of lug receiving holes formed therethrough for mounting the wheel to an axle of the vehicle. The rim is fabricated from steel, aluminum, or other alloys, and includes an inboard tire bead seat retaining flange, an inboard tire bead seat, an axially extending well, an outboard tire bead seat, and an outboard tire bead seat retaining flange. In some instances, a three-piece wheel construction having a mounting cup secured to the disc is used. In both types of constructions, the outer annular portion of the disc is typically secured to the rim by welding.

A conventional full face fabricated vehicle wheel is distinguished from other types of fabricated wheels by having a one-piece wheel disc construction. In particular, the full face wheel includes a “full face” disc and a “partial” rim. The full face disc can be formed cast, forged, or fabricated from steel, aluminum, or other alloys. The full face disc includes an inner annular wheel mounting portion and an outer annular portion which defines at least a portion of an outboard tire bead seat retaining flange of the wheel. The wheel mounting portion defines an inboard mounting surface and includes a center pilot or hub hole, and a plurality of lug receiving holes formed therethrough for mounting the wheel to an axle of the vehicle. The partial rim is fabricated from steel, aluminum, or other alloys, and includes an inboard tire bead seat retaining flange, an inboard tire bead seat, an axially extending well, and an outboard tire bead seat. In some instances, the outboard tire bead seat of the rim and the outer annular portion of the disc cooperate to form the outboard tire bead seat retaining flange of the full face wheel. In both types of constructions, the outboard tire bead seat of the rim is positioned adjacent the outer annular portion of the disc and a weld is applied to secure the rim and the disc together.

A typical euroflange type of vehicle wheel may be formed as a one piece cast wheel or may be as a two piece fabricated euroflange vehicle wheel having a cast outer disc and a full face wheel disc and a partial wheel rim, such as shown in U.S. Pat. No. 5,564,792 to Archibald. In both types of constructions, the wheel does not include an outboard tire bead seat retaining flange having a generally axially outwardly extending lip or portion capable of receiving a conventional wheel balance weight.

SUMMARY OF THE INVENTION

This invention relates to a full face fabricated euroflange type of vehicle wheel.

According to one embodiment, the full face fabricated euroflange vehicle wheel comprises a full face wheel disc defining an axis and formed from a suitable material, the wheel disc having an outer end; and a wheel rim formed from a suitable material and having an outer end joined to the outer end of the wheel disc by at least one weld to produce the fabricated euroflange vehicle wheel; wherein the fabricated euroflange vehicle wheel includes only a generally radially outwardly extending outer end formed by a combination of at least a portion of two of the outer end of the wheel disc, the outer end of the wheel rim and the at least one weld.

According to another embodiment, the method for producing a full face fabricated euroflange vehicle wheel comprising the steps of: (a) providing a full face wheel disc defining an axis and formed from a suitable material, the wheel disc having an outer end; and (b) providing a wheel rim formed from a suitable material and having an outer end; and (c) positioning the outer ends of the wheel disc and wheel rim in a predetermined position relative to each other; and (d) joining the wheel disc and the wheel rim together by at least one weld to produce the fabricated euroflange vehicle wheel, wherein the fabricated euroflange vehicle wheel includes only a generally radially outwardly extending outer end formed by a combination of at least a portion of two of the outer end of the wheel disc, the outer end of the wheel rim and the at least one weld.

According to yet another embodiment, the full face fabricated euroflange vehicle wheel comprises: a full face wheel disc defining an axis and formed from a suitable material, the wheel disc having an outer end defining a first thickness; and a wheel rim formed from a suitable material and having an outer end joined to the outer end of the wheel disc by at least one weld to produce the fabricated euroflange vehicle wheel, the outer end of said wheel rim defining a second thickness; wherein the fabricated euroflange vehicle wheel includes only a generally radially outwardly extending outer end having a predetermined thickness defined by a combination of the first thickness of the outer end of the wheel disc and the second thickness of the outer end of the wheel rim.

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.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring now to the drawings, there is illustrated inFIG. 1a first embodiment of a full face fabricated euroflange type of vehicle wheel, indicated generally at10, and showing the initial assembly of the vehicle wheel. The vehicle wheel10can be of any suitable type of material or materials, such as for example, steel, aluminum and alloys thereof and, in accordance with the present invention as will be discussed below, is operative to produce a “euroflange” type of vehicle wheel, a portion of which is shown inFIG. 1B. As used herein, the term euroflange type of vehicle wheel means that the associated vehicle wheel does not include an outboard tire bead seat retaining flange having a generally axially outwardly extending lip or portion capable of receiving a conventional wheel balance weight. Although the present invention is illustrated and described in conjunction with the particular euroflange type of full face fabricated vehicle wheel constructions disclosed herein, it will be appreciated that the invention can be used in conjunction with other kinds of full face fabricated euroflange vehicle wheel constructions.

As shown inFIG. 1, the initial assembly of the vehicle wheel10includes the positioning of a wheel disc, indicated generally at12, and a wheel rim, indicated generally at30, relative to one another in a predetermined position. The wheel disc12can be of any suitable construction and in the illustrated embodiment the wheel disc12defines a wheel axis X and includes a center pilot hole14, a plurality of lug bolt receiving holes16spaced around the pilot hole14(only one of such lug bolt receiving holes16illustrated inFIG. 1), a plurality of spokes18, and an outer end, indicated generally at20. The lug bolt receiving holes16receive lug bolts (not shown) and nuts (not shown) for securing the vehicle wheel10on an axle (not shown) of a vehicle. Alternatively, the construction, material and/or make-up of the wheel disc12may be other than illustrated if so desired.

In the illustrated embodiment, the outer end20of the wheel disc12is inverted or turned inwardly so as to extend generally axially inwardly toward the rim30(i.e., downwardly when viewed inFIG. 1), and generally parallel with respect to the wheel axis X. As best shown inFIG. 1A, the outer end20includes a first or outer surface22, a second or inner surface24, and a third or end surface26. In the illustrated embodiment, the first surface22includes a first portion having a non-curved or generally straight outer surface22A, a second portion having a curved or radiused outer surface22B, and a third portion having a non-curved or generally straight outer surface22C. The second surface24includes a first portion having a non-curved or generally straight outer surface24A, a second portion having a curved or radiused outer surface24B, and a third portion having a non-curved or generally straight outer surface24C. The third surface26includes a generally straight outer surface26A.

In the illustrated embodiment, the outer surfaces22A,24A and26A of the surfaces22,24and26, respectively, are generally parallel to each other and generally perpendicular with respect to the wheel axis X. The outer surfaces22C and24C of the surfaces22and24, respectively, are generally parallel with respect to each other and generally parallel with respect to the wheel axis X. Alternatively, the construction and/or make-up of outer end20of the wheel disc12may be other than illustrated if so desired.

The wheel rim30can be of any suitable type of construction and in the illustrated embodiment the wheel rim30includes an inboard tire bead seat retaining flange32, an inboard tire bead seat34, a well36, an outboard tire bead seat38, and an outer end, indicated generally at40. In the illustrated embodiment, the end outer40of the wheel rim30is inverted or turned outwardly so as to extend generally radially outwardly (i.e., to the right when viewed inFIG. 1), and generally perpendicular with respect to the wheel axis X.

As best shown inFIG. 1A, the outer end40includes a first or outer surface40A, a second or inner surface40B, and a third or end surface40C. In the illustrated embodiment, the outer surface40A and the inner surface40B of the outer end40are generally parallel to each other and generally perpendicular with respect to the wheel axis X, and the end surface40C is generally parallel with respect to the wheel axis X. Alternatively, the construction and/or make-up of outer end40of the wheel rim30may be other than illustrated if so desired.

As shown inFIGS. 1 and 1A, the initial assembly of the disc12and the rim30preferably positions the outer surface22C of the end20of the disc12a predetermined generally radial distance A from an axis X1defined by outer surfaces of the bead seats34and38. Preferably, in the illustrated embodiment, the distance A is approximately 17.50 mm. As a result of this, in the illustrated embodiment there is preferably defined gap or “weld receiving” pocket, indicated generally at42, which extends a generally radial distance B between the end surface40C of the outer end40of the rim12and the inner surface24C of the end20of the disc12for a purpose to be discussed below.

Also, as shown in the illustrated embodiment, the initial assembly of the disc12and the rim30preferably positions the inner surface22A of the end20of the disc12a predetermined generally axial distance C from the outer surface40A of the rim30. Preferably, the distance C is in the range from about 9 mm to about 14 mm. More preferably, the distance C is in the range from about 11 mm to about 13.5 mm.

Also, as shown in the illustrated embodiment, preferably a generally axial distance D is defined between the inner surface22A of the end20of the disc12and the outer surface26A of the end20of the disc. Preferably, as shown in the illustrated embodiment, the distance D is greater than the distance C so as to define an “overhang area” of the outer end20of the disc12which extends a predetermined generally axial distance E for a purpose to be discussed below. Alternatively, one or more of the distances A, B, C and/or D may be other than illustrated if so desired.

Following the initial assembly of the disc12and the rim30as shown inFIGS. 1 and 1A, the disc12and the rim30are joined together as shown inFIG. 1B. As shown therein, to accomplish this in the illustrated embodiment, welds W1and W2are provided to join the disc12and the rim30together. The first weld W1is deposited in a first fit-up area, indicated generally at F1inFIG. 1A, which is defined in the gap42by the respective surfaces40C,24A and24C of the rim30and the disc12, and the second weld W2is deposited in a second fit-up area, indicated generally at F2inFIG. 1A, which is defined by the respective surfaces30A and12A of the rim30and the disc12. Alternatively, one or both of the welds W1and W2may be other than disclosed.

Following the welding of the disc12and the rim30as shown inFIG. 1A, an exposed outer portion or “weldment area” of the weld W1is finish machined as shown inFIG. 1C. As shown therein, during the finish machining operation, the overhang portion of the outer end20of the disc12is preferably also machined along with the outer portion of the weld W1so as to be generally in the same plane or generally flat with the outer surface40A of the end40of the rim30. As a result of this, the wheel10is provided with a finished generally radially outwardly extending outboard end or lip, indicated generally at50inFIG. 1C, having a generally constant or uniform outer surface50A along the associated surfaces of the end40of the rim30, the weld W1, and the end20of the disc12and is operative to generally maintain the distance C between the outer surface22A of the end20of the disc12and the outer surfaces40A and50A of the rim and the wheel10, respectively. It is preferred that outer surface50A be generally smooth (i.e., no bumps or edges), to thereby accommodate the associated tire. Also, while in the illustrated embodiment the surfaces12A and50A are shown as being generally parallel with respect to one another, one or both of the surfaces22A and50A can be non-parallel (i.e., angled).

Referring now toFIGS. 2,2A and2B and using like reference numbers to indicate corresponding parts or elements, there is illustrated a second embodiment of a full face fabricated euroflange type of vehicle wheel, indicated generally at200. In this embodiment, a wheel rim230includes an outer end240which is inverted or turned inwardly so as to extend generally radially inwardly (i.e., to the left when viewed inFIG. 2), and generally perpendicular with respect to a wheel axis X. In the illustrated embodiment, the outer ends240and20are disposed adjacent one another in a predetermined position and a first inner weld W3, a second outer weld W4, and a third outer weld W5are used to join the rim230and the disc12together. The welds W3and W4may be similar to the welds W1and W2of the first embodiment.

In addition, in this embodiment, the outer end20of the disc12preferably does not have the overhang portion like in the first embodiment of FIGS.1and1A-1C; however, the outer end20of this embodiment may have the overhang portion like in the first embodiment if so desired. Also, while the two separate outer welds W4and W5are preferred due to the weld W4being a “penetrating” type of weld adapted to join the rim and disc together and the weld W5being a “filler” type weld, a single outer weld may be used if so desired.

Referring now toFIGS. 3A and 3Band using like reference numbers to indicate corresponding parts or elements, there is illustrated a third embodiment of a full face fabricated euroflange type of vehicle wheel, indicated generally at300. In this embodiment, a rim330includes a generally flat outer end340and a disc312includes a generally flat outer end320. In the illustrated embodiment, the outer ends340and320are disposed adjacent one another in a predetermined position and a first inner weld W6and a second outer weld W7are used to join the rim330and the disc312together.

Referring now toFIGS. 4A and 4Band using like reference numbers to indicate corresponding parts or elements, there is illustrated a fourth embodiment of a full face fabricated euroflange type of vehicle wheel, indicated generally at400. In this embodiment, a rim430includes a generally S-shaped outer end440having a first portion440A which extends in a generally radially outwardly direction and a second portion440B which extends in a generally axially outwardly direction, and a disc412includes a generally flat outer end420. In the illustrated embodiment, the outer ends440and420are disposed adjacent one another in a predetermined position and a first inner weld W8and a second outer weld W9are used to join the rim430and the disc412together.

Referring now toFIG. 5and using like reference numbers to indicate corresponding parts or elements, there is illustrated a fifth embodiment of a full face fabricated euroflange type of vehicle wheel, indicated generally at500. In this embodiment, a rim530includes a generally inverted or turned radially outwardly extending outer end540and a disc512includes a generally flat outer end520having a radially extending outwardly turned outer end portion520A. Alternatively, the outer end520can have an outer end portion520A′, as shown in phantom inFIG. 5.

In the illustrated embodiment, preferably a first or outer weld W10is used to join the rim530and the disc512together. Alternatively, a second or an inner weld (not shown), may also be provided to join the rim530and disc512together. In the embodiment ofFIG. 5(as well as the embodiments ofFIGS. 6 and 7), the outer end of the wheel following the machining operation thereof is not shown but it is understood that such outer end may be machined in a manner similar to that described and illustrated above in connection with the embodiments ofFIGS. 1 to 4.

Referring now toFIG. 6Aand using like reference numbers to indicate corresponding parts or elements, there is illustrated a sixth embodiment of a full face fabricated euroflange type of vehicle wheel, indicated generally at600. In this embodiment, a rim630includes an outer end640having a turned back portion640A which provides an outer shoulder640B and a generally flat portion640C, and a disc612includes a stepped outer end620which provides an inner shoulder620A and a generally flat portion620B. In the illustrated embodiment, the outer ends640and620are disposed adjacent one another in a predetermined position (e.g., with the respective shoulders640A and620A contacting each other), and a first inner weld W11is used to join the rim630and the disc612together. Alternatively, as shownFIG. 6B, a second outer weld W12may also be used to join the rim630and the disc612together if so desired.

Referring now toFIG. 7and using like reference numbers to indicate corresponding parts or elements, there is illustrated a seventh embodiment of a full face fabricated euroflange type of vehicle wheel, indicated generally at700. In this embodiment, a rim730includes a generally flat outer end740and a disc712includes a reverse-curled or generally U-shaped outer end720. In the illustrated embodiment, the outer ends740and720are disposed adjacent one another in a predetermined position and a first inner weld W13and a second outer weld W14are used to join the rim730and the disc712together.

Referring now toFIG. 8and using like reference numbers to indicate corresponding parts or elements, there is illustrated an eighth embodiment of a full face fabricated euroflange type of vehicle wheel, indicated generally at800. In this embodiment, a rim830includes a generally flat outer end840and a disc812includes a generally flat outer end820having an increased thickness T2therein compared to a thickness T1generally defined by the remainder of the disc. For example, if the distance C of about 12 mm is desired, the outer end840of the rim830could be approximately 4 mm thick, thickness T2could be approximately 8 m and thickness T1could be approximately 4 mm. Alternatively, the thicknesses of one or both of the rim830and/or the disc812may be other than disclosed if so desired. In the illustrated embodiment, the outer ends840and820are disposed adjacent one another in a predetermined position and a first inner weld W15and a second outer weld W16are used to join the rim830and the disc812together.

Referring now toFIG. 9and using like reference numbers to indicate corresponding parts or elements, there is illustrated a ninth embodiment of a full face fabricated euroflange type of vehicle wheel, indicated generally at900. In this embodiment, a rim930includes a generally flat outer end940and a disc912includes a generally flat outer end920having an increased thickness T4compared to a thickness T5of the rim30. For example, if the distance C of about 12 mm is desired, the thickness T4could be approximately 8 m and thickness T5could be approximately 4 mm. Alternatively, the thicknesses of one or both of the rim30and/or the disc12can be other than disclosed if so desired.

In the illustrated embodiment, the outer ends940and920are disposed adjacent one another in a predetermined position and a first outer weld W17is used to join the rim930and the disc912together. Alternatively, a second inner weld (not shown) may also be used to join the rim930and the disc912together if so desired. Also, the outer end of the disc912prior to the machining operation may have a profile as shown in phantom at920A inFIG. 9.

Referring now toFIG. 10and using like reference numbers to indicate corresponding parts or elements, there is illustrated a tenth embodiment of a full face fabricated euroflange type of vehicle wheel, indicated generally at1000. In this embodiment, a rim1030includes a reversed or curled outer end1040and a disc1012includes a generally flat outer end1020having an increased thickness T6compared to a thickness T7of the rim30.

Also, in this embodiment, a remote end or end face1040A of the outer end1040of the rim1030contacts the disc1012so that a gap, indicated generally at1050, having a generally axial distance F is defined between respective opposed adjacent surfaces1030A and1012A of the rim1030and the disc1012. For example, if the distance C of about 13.5 mm is desired, the thickness T6could be approximately 6 m, the thickness T7could be approximately 4 mm and the distance F of the gap1050could be approximately 3.5 mm. Alternatively, the thicknesses of one or both of the rim1030and/or the disc1012may be other than disclosed and/or the distance F of the gap1050can be other than disclosed if so desired.

In the illustrated embodiment, the outer ends1040and1020are disposed adjacent one another in a predetermined position and a first outer weld W18is used to join the rim1030and the disc1012together. Alternatively, a second inner weld (not shown), which would be deposited in the gap1050, may also be used to join the rim1030and the disc1012together if so desired. Also, the outer end1020of the disc1012prior to the machining operation may have a profile as shown in phantom at1020A inFIG. 10.

Referring now toFIG. 11and using like reference numbers to indicate corresponding parts or elements, there is illustrated an eleventh embodiment of a full face fabricated euroflange type of vehicle wheel, indicated generally at1100. This embodiment is similar to the embodiment shown inFIG. 10except that an outer end1120of a disc1112includes a groove1120B formed therein adapted to receive a remote end1140A of an outer end1140of a rim1130. The groove1120B extends a predetermined axial depth G.

In the illustrated embodiment, the outer ends1140and1120are disposed adjacent one another in a predetermined position and a first outer weld W19is used to join the rim1130and the disc1112together. Alternatively, a second inner weld (not shown) may also be used to join the rim1130and the disc1112together if so desired. Also, the outer end1120of the disc1112prior to the machining operation may have a profile as shown in phantom at1120A inFIG. 11.

One advantage of the present invention is that a full face fabricated euroflange type of vehicle wheel may be manufactured without having to use a casting method to produce a cast wheel disc of the associated known euroflange vehicle wheel.

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.