Aerodynamic wheel covers and mounting assemblies

Aerodynamic wheel covers may include a hub assembly coupled with a hub of a large vehicle, such as a truck. A base assembly may be coupled to the hub assembly, and a disk assembly may be coupled with the base assembly such that removal and installation of the disk assembly may be accomplished without tools.

TECHNICAL FIELD

This invention relates to methods of constructing and affixing aerodynamic wheel covers to the wheels of land vehicles, especially heavy trucks, whereby the wheel covers have improved maintenance, operation, functionality, cost-effectiveness, appearance, aerodynamics and fuel efficiency.

BACKGROUND

Wheel covers are common on cars, in part because the wheel rims provide a reliable mechanism for attachment and in part because car owners generally do not need to frequently access the lug nuts or other components covered by a hub cap.

In contrast, wheel covers for large vehicles such as semis are rarely used. Neither dual-wheels nor single-wide wheels are configured so that a wheel cover can be snapped into engagement as in the case with many passenger car wheel/wheel disk arrangements. Instead, dual wheels and single-wide wheels, especially on tractor-trailer vehicles and other large vehicles, are characterized by the substantial depth from the plane of the outer wheel rim inward to the region of the wheel hub where the wheel is attached to a brake drum, axle rotor, additional wheel or the like. This characteristic makes it difficult to secure a wheel cover to a dual wheel or single-wide wheel. Furthermore, a driver, mechanic or operator may need to inspect or access a hub odometer, an oil reservoir gauge, lug nuts, tire inflation valve, or some other component.

Some prior art systems and devices include rigid wheel covers. A disk, manufactured from aluminum or some other metal, is secured to a bracket using screws, bolts, or other hardware. A drawback to this type of wheel cover is the rigid disk is easily damaged by contact with a curb, post, or other traffic device. The time required to install and remove the cover, and the likelihood of a rigid cover rattling, making noise, and coming loose are also disadvantages. Some prior art methods involve installing a frame and then attaching (such as by using a zipper) a fabric shield to the frame. In operation, prior art approaches using a zipper typically utilize the inner bead or “drop-center” of the wheel. As such, prior art wheel covers may touch the outer flange but effectively “grabs” inside. A drawback is that this type of wheel cover does not fit all types of wheels, such as single-wide wheels, and requires the wheels to be cleaned when they may be heavily soiled and difficult to clean.

Some prior art methods of attaching a wheel cover to a truck wheel include a hub feature, such as a mounting bracket, that projects outwardly from the end of the wheel hub approximately to the plane of the wheel rim. However, these attachment methods require tools and significant labor for installation or removal, which is necessary to perform most repairs or maintenance on the wheels.

Some prior art methods include a peripheral mounting method in which clips or other means attach a wheel cover to the outer flange of the wheel rim. However, attachment brackets which rely on hooks or spring clips are susceptible to loosening under stress and are difficult to install. Furthermore, prior art methods of mounting wheel covers to the periphery of the wheel have shortcomings due to the difficulty of rigidly attaching a clip or other mounting feature to the outer wheel rim or flange. Further, the depth from the plane of the outer wheel rim inward to the region of the wheel hub where the inner diameter of the wheel is larger than elsewhere is typically several inches on dual wheels and single-wide wheels. As a result, these wheels cannot accommodate a wheel cover that can normally be snapped into engagement with the wheel outer flange (as in the case with many passenger car wheel/wheel disk arrangements, where conventional hub caps are used).

Furthermore, many of the prior art attachment systems are undesirably complex, either in the number of components required and/or the labor needed for installation and removal. The manufacturing costs of systems having a large number of components can be prohibitive.

Many prior art wheel covers are constructed of a solid surface with no openings to allow for ventilation that may assist to cool the hub area and adjacent brake components or to provide an exit means for water and debris.

SUMMARY

One aspect of embodiments described herein is to provide aerodynamic wheel covers and means for attaching an aerodynamic wheel cover to a dual wheel or single-wide wheel assembly on a large vehicle.

Another aspect of embodiments described herein is to provide wheel cover mounting arrangements that allow for a range of geometric shapes of the wheel cover disk.

Another aspect of embodiments described herein is to provide wheel cover mounting arrangements that include an air hose extension and a valve positioned on the disk, the disk components (base),or in an opening adjacent the disk to provide means for inspecting or maintaining tire pressure.

Another aspect of embodiments described herein is to provide wheel cover mounting arrangements such that a wheel cover can be installed and removed without tools, or with very readily-available tools, and with minimal time and effort such that an individual removing and installing the wheel covers is not significantly inconvenienced by the wheel cover.

The mechanism and associated wheel cover mounting method disclosed herein improve the wheel cover installation and removal process since the method requires no tools or a reduced number of tools and can be accomplished faster and simpler, with fewer parts than existing wheel cover mounting methods and mechanisms.

An advantage to embodiments disclosed herein may be that a wheel cover is less susceptible to torsion or awkward loading like center-mounted disks, and that the wheel cover does not require an “inset” bead such as found in passenger cars/trucks.

An advantage may be the ability to provide advertising or other information for display to passers-by or an operator or maintenance personnel.

In one broad respect, embodiments disclosed herein may include an aerodynamic wheel cover assembly, comprising a bracket assembly configured to couple to a wheel, a base assembly for coupling with the bracket assembly, a piston for positioning in the inner perimeter, a spring having a first end in contact with the base and a second end in contact with the piston, an alignment bushing having a plurality of arms separated by a plurality of notches, and a disk assembly compatible with the base assembly. The base assembly may include a base having an inner wall forming a cylindrical perimeter and a plurality of extensions separated by a plurality of channels. The piston may include an outboard side formed with a plurality of ribs separated by a plurality of notches and a plurality of spokes positioned between the extensions. The disk assembly may include an inner ring having a plurality of tabs, a resilient disk, and an outer ring configured to contact the wheel when the disk assembly is coupled to the base assembly. The plurality of tabs may be translatable in a direction substantially parallel to a longitudinal axis of the piston to a first position to deflect the spring relative to the longitudinal axis. The plurality of tabs may also be rotatable about the longitudinal axis to a second position, whereby force applied by the spring maintains the plurality of tabs between the plurality of ribs. In some embodiments, the inner ring comprises a metal ring. In some embodiments, the inner ring is formed with a thickness greater than a thickness of the resilient disk. In some embodiments, the piston comprises an inner shaft, wherein the plurality of spokes connect the inner shaft to the outer ring of the piston and wherein depression of the inner shaft depresses the spring in the piston. In some embodiments, one or more of the base, the piston and the resilient disk are injection-molded.

In another broad respect, embodiments disclosed herein may include a method for manufacturing an aerodynamic wheel cover assembly. A method may include forming a base assembly comprising a base having an inner wall and one or more extensions separated by a plurality of channels, forming a piston, forming an alignment bushing, forming a bracket assembly comprising a fixed bracket and an adjustable bracket, forming a disk assembly and assembling the base assembly with a spring having a first end in contact with the base and a second end in contact with the piston. The piston may be formed having an outboard side formed with a plurality of ribs separated by a plurality of notches and a plurality of spokes, each spoke having a width less than an arc length between adjacent extensions, the plurality of spokes positioned between the extensions. The alignment bushing may be formed with a plurality of arms separated by a plurality of notches, wherein each arm has an arc length corresponding approximately to the arc length of each notch in the piston. The disk assembly may be formed with an inner ring having a plurality of tabs, a resilient disk, and an outer ring configured to contact the wheel when the disk assembly is coupled to the base assembly. The inner ring may be fixed to the disk or it may spin freely. Locking means may be provided such as riveting, adhesives, etc. The inner ring may be insert-molded into the disk via injection molding techniques. The disk may receive the inner ring via one-way clips or the like that secure the ring in place by using molded features in an injection molded disk. Notches around the perimeter of the disk may reduce the potential for shear load failure when using double-sided tape, for example. The disk may be molded to accommodate a removable rubber or plastic center cap to seal the base assembly from debris, etc., and also to provide a cosmetic and more aerodynamic surface. A plastic center cap may be configured with a chain or other means for maintaining the cap in close proximity to the disk when it is moved away from the center such that the cap, if not properly positioned on the wheel cover, would be attached to the wheel cover and an operator may be less likely to misplace the cap when it is removed. The piston may be provided with injection-molded inserts in lieu of extensions, for example, to provide additional clamping strength and reduced cost. The plurality of tabs may be translatable in a direction substantially parallel to a longitudinal axis of the piston to a first position to deflect the spring relative to the longitudinal axis. The plurality of tabs may also be rotatable about the longitudinal axis to a second position, whereby force applied by the spring maintains the plurality of tabs between the plurality of ribs. In some embodiments, one or more of the base, piston, alignment bushing, and inner ring are machined. In some embodiments, one or more of the base, piston, and alignment bushing are injection molded. In some embodiments, the inner ring is machined from stainless steel. In some embodiments, forming the piston comprises forming an inner shaft coupled to the ring with a plurality of spokes.

In another broad respect, embodiments disclosed herein may include a system for maintaining an aerodynamic cover on a wheel. The system may include a disk assembly, a base assembly, a piston at least partially received in the base, a spring having a first end in contact with the base and a second end in contact with the piston, and a bracket assembly configured to couple to a hub of a wheel. The disk assembly may include an inner ring having a plurality of tabs, a resilient disk, and an outer ring. The base assembly may include a base having an inner wall having one or more extensions separated by a plurality of channels. The piston may have an outboard side formed with a plurality of ribs separated by a plurality of notches and one or more spokes. Each spoke may have a width less than an arc length between adjacent extensions. Each spoke may be positioned between each extension to align and prevent rotation. Other ways to achieve rotational alignment with the piston and the base may include selecting complementary geometric shapes. The plurality of tabs may be translatable in a direction substantially parallel to a longitudinal axis of the piston to a first position to deflect the spring relative to the longitudinal axis. The plurality of tabs may also be rotatable about the longitudinal axis to a second position, whereby force applied by the spring maintains the plurality of tabs between the plurality of ribs. In some embodiments, the axial extensions are formed on the base. In some embodiments, the axial extensions are formed on the piston. In some embodiments, the piston further includes an inner shaft coupled to the outer ring via the spokes. In some embodiments, the disk assembly comprises a disk formed from a resilient material. In some embodiments, the disk assembly comprises a disk having a selected concavity, wherein the disk is formed to be in a first configuration when the disk does not contact a wheel and in a second configuration when the disk contacts a wheel. In some embodiments, the first configuration is concave. In some embodiments, the first configuration is planar. In some embodiments, the second configuration is convex.

DETAILED DESCRIPTION

Tractor-trailers travel significant distances every year. Consequently, the cumulative effect of even incremental amounts of drag on a tractor-trailer can lead to significant increases in overall operating costs. Such increased transportation costs are typically absorbed by consumers of the products transported. One significant source of drag on tractor-trailers, and hence increased transportation costs, are the wheel assemblies of the tractor-trailers. In general, the aerodynamic drag of a vehicle increases when air flow is affected by a wheel opening, especially deep wheel openings commonly found on tractor-trailer vehicles. Consequently, there is a need for wheel covers that decrease drag. However, as discussed previously, previous solutions for attaching covers to hubs are unsatisfactory for use with tractor trailers. Accordingly, embodiments described herein provide mechanisms and methods for attaching cover assemblies to wheel assemblies (as used herein, the term “wheel assembly” may refer to a single wheel or a dual wheel assembly, particularly as it relates to a tractor-trailer vehicle).

According to one embodiment, a wheel cover assembly may include a removable wheel cover or disk assembly coupled with a fixed hub mounting assembly that is mounted or otherwise coupled to a wheel assembly. The wheel assembly may be a single wheel or a dual wheel assembly, particularly as it relates to a tractor-trailer vehicle, or other type of wheel assembly.FIGS. 1A-1Bdepict perspective and side views of one embodiment of aerodynamic wheel cover assembly100including disk assembly300mounted on a hub mounting assembly200which is coupled to wheel assembly6. In some embodiments, disk assembly300may be formed as outer retaining ring310coupled with spokes305to inner ring320and disk315. Disk315may be single piece or may be formed as disk inserts315. Outer retaining ring310, spokes305and disk315may be constructed separately or may be formed as a monolithic disk assembly300. Disk315may be formed generally planar or non-planar. Non-planar disks315may have a substantially conical or concave form. In some embodiments, disk315may be oriented with a concavity facing inboard and wheel cover assembly100may be configured such that installation of disk assembly300biases disk315. Biasing disk315may lessen the concavity, may result in an otherwise planar disk having a negative concavity (i.e., disk315has a convex shape) or may otherwise change the configuration of the disk from an initial configuration to a second configuration or flexion. In some embodiments, disk assembly300provides a substantially continuous surface to facilitate aerodynamic flow around wheels6. In other embodiments, disk assembly300may be configured to facilitate aerodynamic flow through the wheel cover, whereby the wheel cover may act as a fan or radial vent, for example. The size, rigidity, concavity/convexity, surface texture, venting features, or contact area with wheel(s)6may be selected to promote a desired air flow around wheel(s)6. Furthermore, portions of disk assembly300may be manufactured with clear material or with openings to allow visual access to components of wheel(s)6.

FIGS. 2A-2Bdepict perspective and side views of an alternate embodiment of an aerodynamic wheel cover assembly100including hub mounting assembly200mounted on wheel assembly6. Attachment or coupling hub mounting assembly200with hub50may involve using hardware52to couple bracket204to hub50, while still allowing access to wheel nuts22. As depicted inFIGS. 2A and 2B, disk assembly300may be formed as an outer retaining ring310coupled with spokes305to inner ring320with disk inserts315. The inner portion40of the rim (e.g., the area encircled by the rim's outboard flange), including the hub50may be exposed for increased circulation, to prevent debris from being trapped inside wheel cover assembly100, to improve cooling, etc.

FIG. 3depicts an exploded view of one embodiment of aerodynamic wheel cover assembly100including hub mounting assembly200and disk assembly300. Hub mounting assembly200may include bracket assembly150and base assembly250. Bracket assembly150may be configured or formed to allow access to components associated with wheel6, such as hub50, the rim, a tire inflation valve, a fluid level indicator, lug nuts, or the like. Bracket assembly150may be fastenable to hub50such that bracket assembly150may be removed or installed using tools. Tools used to remove bracket assembly150may be standard tools (e.g., sockets) or specialized, and may include hardware and locking mechanisms to prevent accidental or unauthorized removal of bracket assembly150. In some embodiments, bracket assembly150may be connected to hub50utilizing studs52or some other pre-existing hardware associated with hub50. In some embodiments, stationary bracket110may be coupled to hub50, such as using hub nuts53threaded onto studs52. Adjustable bracket125may be coupled fixedly or pivotally to stationary bracket204using hardware115or some other mechanical means. Adjustable bracket125may be selectively coupled to stationary bracket204such that the position of the outboard end of adjustable bracket125may be selected. That is, in the embodiment shown, the outboard position of base assembly mounting platform127may be adjusted. Selective adjustment of adjustable bracket125may be performed utilizing a series of holes, slots, or other means of linear positioning.

Also depicted inFIG. 3, hub mounting assembly200may include base assembly250. Base assembly250may be coupled to hub50via bracket assembly150to mount disk assembly300. In some embodiments, base assembly250includes base210, resilient member or spring212, piston214and alignment bushing220. Base assembly250may be coupled with adjustable bracket125using hardware or other mechanical, thermal or chemical means, or may be formed integral with adjustable bracket125.

FIGS. 4A-4Bdepict top and perspective views of one embodiment of bracket assembly150having adjustable bracket125for use with an aerodynamic wheel cover and a system for mounting an aerodynamic wheel cover on a wheel assembly. Bracket assembly150may be coupled with hub50using nuts53on studs52. In some embodiments, slots116and openings117may allow adjustments of the height H of adjustable bracket125relative to stationary brackets110to accommodate hubs of various heights, and openings350and127allow adjustments to width W of bracket125to allow adjustments for various diameters of hubs50, or to accommodate other devices, for example automatic inflators, on hub50

FIG. 5depicts an exploded view of components of one embodiment of base assembly250. In some embodiments, base assembly250comprises base210, piston214, spring212, and alignment bushing220. In some embodiments, inner walls of base210have a selected depth and recessed area211for retaining spring212. In some embodiments, inner walls209form a cylinder. Inner walls209defines a space within which piston214is able to translate axially. Piston214comprises ring218about an inner shaft215aligned relative to longitudinal axis A-A. Ring218includes notches216of arc length D separated by ribs229of arc length C. Inner shaft215includes a first end213for retaining a second end of spring212and a second end222. Inner shaft215is joined to ring218by a set of radially extending spokes232separated by openings of approximately a width or an arc length E.

Alignment bushing220includes an outboard area having a set of outwardly extending radial arms217having an arc length of approximately D, separated by notches230of an arc length of approximately C. A set of extensions221extend inboard and have an arc length of approximately E. An aperture234is sized so that second end222of inner shaft215can pass.

In operation, extensions221can pass through the gaps between spokes232, with the spokes fitting in channels231. Alignment bushing220can be coupled to base210. Alignment bushing220may be bolted, welded, glued, epoxied, or otherwise mechanically, thermally, or chemically coupled to base210to inhibit movement of alignment bushing220relative to base210. In some embodiments, alignment bushing220and base210comprise apertures206that can be aligned such that a pin, screw, rivet or other hardware (not shown) can be inserted to hold alignment bushing220relative to base210.

Biasing member212can bias piston214toward alignment bushing220such that ribs229fit in notches230and radially extending arms217fit in notches216. The second end of inner shaft215can be accessible through aperture234. By pressing on second end222of inner shaft215, piston may be translated in an inboard direction such that there is clearance between the inboard surfaces of radially extending arms217and the outboard surfaces of ribs229. Consequently, a disk assembly300may rotate for installation and removal, as discussed below.

FIGS. 6 and 7depict perspective views of another embodiment of base assembly250. Embodiments disclosed herein may include features for preventing rotation of piston214in base assembly250. In the embodiment ofFIGS. 6 and 7, piston214is similar to that depicted inFIG. 5, but base210includes extensions227that extend outboard, rather than alignment bushing220including projections221that extend inboard. Although not illustrated, a biasing member, such as depicted inFIG. 5, may bias piston214away from base210. Channels237have a width or arc length P to accommodate spokes232of arc length0. Channels237in base210accommodate spokes232to ensure alignment of extension227through apertures241. Each extension227is sized to extend through apertures241between spokes232. For example, extensions227may have a width M sized to fit through aperture241having width N. Base210has an inner surface272for contact with outer surface273of outer ring218of piston214. Alignment bushing220, in the example ofFIGS. 6-7can be a relatively flat sheet piece having radially extending arms217separated by notches230and having an aperture234to accommodate the second end of piston214.

Biasing member212can bias piston214toward alignment bushing220such that ribs220fit in notches230and radially extending arms217fit in notches216. The second end of inner shaft215can be accessible through aperture234. By pressing on second end of inner shaft215, piston may be translated in an inboard direction such that there is clearance between the inboard surfaces of radially extending arms217and the outboard surfaces of ribs229. Consequently, a disk assembly300may rotate for installation and removal, as discussed below.

Embodiments disclosed herein include a system that allows tool-free installation and removal of a resilient disk. To reduce binding and to better align the components, the shape of each extensions221or227, the width or arc length of channels231or237, the arc length of spokes232, the width and arc length of apertures215, the size of inner shaft215and aperture235can be selected such that piston214is able to translate relative to alignment bushing220. In operation, piston214is able to translate relative to alignment bushing220to allow second end222to be recessed with, flush with or extended beyond alignment bushing230and to allow ribs229to be recessed with, flush with or extend axially beyond radial arms217.

As discussed below, tabs of a disk assembly300are able to be positioned in notches230and in contact with ribs229and depressed and rotated behind radial arms217into notches216, and may use edge262of extensions221or227as a guide and with channels231or237small enough such that the tabs of the disk assembly do not bind or hang on axial extensions221or227. In use, spring212exerts a force on piston214to maintain axial bias of ribs229of piston214in notches230of alignment bushing, thereby trapping the tabs of the disk assembly between the surfaces243of notches216and the radial arms217of the alignment bushing220.

Advantageously, embodiments such as those described herein may be manufactured from metal (including alloys) or polymers. In some embodiments, components may be manufactured using CNC techniques. Some embodiments disclosed herein may be formed with CNC techniques on a three axis machine, which may advantageously allow for increasing or decreasing the scale of a device, and which may advantageously reduce production costs.

FIGS. 8-10depict perspective views of one embodiment of base assembly250, illustrating one mode of operation. In a first biased position, ribs229and notches230may be aligned (and corresponding notches216and radial arms217may also aligned) such that the force exerted by spring212biases piston214to a first extended axial position. In other biased positions, forces exerted on piston214may depress spring212such that a gap G is formed between surface243of rib229and surface233(i.e., back side) of radial arms217. For example, a second biased position may be defined as a position of piston214where the gap G is large enough that the distance between the outboard surfaces of ribs219and the inboard surfaces of radial arms217is greater than the thickness of corresponding tabs on a disk assembly, thereby allowing the tabs of the disk assembly to be positioned between ribs229and radial arms217.FIG. 9depicts a partial perspective view of wheel cover assembly100in which piston214is in a second position such that tabs207of a disk assembly300are inserted through notches230(see e.g.,FIG. 6) and able to rotate from a first position aligned with notches230to a second position aligned with notches216(see e.g.,FIG. 6).

In a third biased position, spring212may exert a force on piston214such that piston214is not considered to be in the second biased position but piston214may not fully translate to the first biased position.FIG. 10depicts a partial perspective view of one embodiment of wheel assembly100in which gap G is smaller than gap G inFIG. 9, illustrating base assembly250being in a third biased position. In this case, the tabs207of disk assembly300may be fully seated in notches216with the piston biasing the tabs207against the radial arms217.

FIGS. 9 and 10further depict an embodiment of disk assembly300in which disk315includes cutouts920, insets910, and rails930. Insets910, cutouts920and rails930may be formed or positioned to accommodate wheel balance weights on a rim, valve stems or other hardware, to increase air flow behind disk315, to provide hand holds to assist in removal and installation of disk assembly300, to provide a desired rigidity to disk assembly300, and other advantages.

In operation, disk assembly300may be positioned in base assembly250to maintain disk assembly300in a desired position.FIGS. 11A-11Fdepict partial and perspective views of one embodiment of aerodynamic wheel cover assembly100and a system for mounting aerodynamic disk assembly300on hub mounting assembly200, illustrating one method for installing a wheel cover on a wheel assembly.

A first step in the mounting process involves aligning disk assembly300with base assembly250.FIGS. 11A and 11Bdepict views of wheel cover assembly100, illustrating a step for aligning disk assembly300with base assembly250. In some embodiments, alignment includes visually checking that tabs207on inner ring202are positioned in notches230of alignment bushing220. Alignment may be performed visually, such as ensuring tabs207cover ribs229, aligning an arrow or other alignment mark244on disk assembly300with an arrow or some other alignment mark245on base assembly200, or using a color, material, or other visual information. Alignment may also be performed using auditory or tactile information or cues, such as by selecting a geometry of the parts. For example, contacting tabs207on inner ring202with radial arms217and rotating wheel cover assembly200until the operator or mechanic hears or feels a click may indicate tabs207of disk assembly300are aligned with ribs229. In one embodiment, alignment of disk assembly300to base assembly250is possible when piston214is in a first biased position, for example when radial arms217have a thickness such that ribs229appear recessed, flush, or above relative to radial arms217.

Once disk assembly300is in a desired position relative to notches230, piston214can be depressed to a second biased position at a selected depth or depth range in cylinder209of base210. Depressing piston214may be accomplished by applying pressure to actuator222, (for example using a thumb or finger) or by applying pressure to tabs207in contact with ribs229.FIGS. 11C and 11Ddepict perspective views of one embodiment of disk assembly300, illustrating advancement of inner ring202axially inward such that tabs207are positioned behind radial arms217(such as shown inFIG. 11D), indicating compression of spring212.

Once piston214is depressed a minimum amount, the gap G created between tab207and the bottom surface of radial arms217allows tabs207to be rotated relative to alignment bushing220and piston214.FIGS. 11E and 11Fdepict perspective views of one embodiment of wheel cover assembly100with disk assembly300.FIG. 11Edepicts disk assembly300rotated at an angle R relative to base assembly250but less than angle L. When tabs207are offset from and rotated relative to radial arms217some angle R that is less than angle L, tabs207contact surfaces219of ribs229to inhibit ribs229(and thus piston214or spring212) from returning to the first biased position such that piston214is in a second biased position. Rotation may be either clockwise or counter-clockwise.

Further rotation of disk assembly300some angle L relative to base assembly250allows tabs207to align with radial arms217aligned with notches216in ring218of piston214. Alignment of tabs207with radial arms217in notches216allows ribs229to translate in notches230to allow piston214to move from the second biased position into a third biased position. In some embodiments, piston214does not translate to the first biased position, but still translates to a biased position that impedes inner ring202of disk assembly300from rotating.FIG. 11Fdepicts a perspective view of one embodiment of wheel cover assembly100in which disk assembly300is rotated angle L to align tabs207with radial arms217, thus allowing ribs229to align in notches230.

A partial release of compressive forces on spring212allow spring212to extend to maintain ribs229in notches230. Maintaining ribs229in notches230provides security to wheel cover assembly100in that piston214is further unable to rotate and disk assembly300is securely coupled with base assembly250. Using steps such as those depicted inFIGS. 11A-11F, disk assembly300with tabs207may be engaged with ribs229on piston214such that disk assembly300is secured to base assembly250, effectively locking disk assembly300yet allowing some motion to accommodate curbs and other objects or users that might contact outer ring180, spoke185, inserts215or other components of disk assembly300.

Removal of disk assembly300may be accomplished by performing these steps in reverse order such that piston214is depressed to the second biased position, disk assembly300is rotated to align tabs207with notches230and piston214such that tabs207can be withdrawn from base assembly250.

In some embodiments, common hardware or machines elements may be utilized, which may reduce overall complexity, reduce manufacturing costs, or other advantages.FIG. 12Adepicts an exploded view of one embodiment in which common machine elements are used instead of custom-made hardware.FIGS. 12B and 12Cdepict embodiments in an assembled position ready to receive a disk assembly. In some embodiments, spring1212and hardware1208and1220may be common, off-the-shelf parts. In some embodiments, bracket1213or hardware1215may be able to replace portions of base assembly250. In some embodiments, such as depicted inFIG. 12A, piston1214may include a single rib1229and a single notch1216, alignment bushing1220may include a single radial arm1217and a single notch1230, and disk assembly300may include tab1207. Hardware1240may be used to couple portions together or to bracket1213.

As those skilled in the art will appreciate after reading this disclosure, embodiments described herein provide many variations of elements but a common push and turn functionality, in which one or more tabs on the disk assembly may be captured by the base assembly to secure the disk assembly to the wheel.

In addition to wheel assemblies discussed above (and shown inFIGS. 1A and 1B), large vehicles may also have wheels mounted on a steer axle.FIG. 13depicts a view of a single wheel assembly, such as found on steer axle70. In this situation, mounting an aerodynamic wheel cover may differ due to the different depth or geometry of steer axle70.FIGS. 14 and 15further show hub odometer1410and oil level indicator1510which may be mounted on a wheel assembly and require further accommodation from wheel cover assembly100.

FIGS. 16A-16Ddepict views of one embodiment of aerodynamic wheel cover assembly100useful for accommodating components mounted to hub50or for mounting to steer axle70. An inner opening diameter of inner ring202may be selected to accommodate maintenance or inspection of components mounted to a hub without removal of the inner ring202. An inner opening diameter of inner ring202may also attach to components typically mounted to the hub50, such as a hub odometer. An advantage of mounting a hub odometer or other component to the inner opening diameter of the inner ring may allow embodiments to utilize all of the benefits disclosed herein. For example, embodiments may utilize a quick release mechanism for easier removal or access for inspections and maintenance.

FIG. 16Bdepicts a side view of one embodiment of wheel cover assembly100mounted on wheel6having a component (e.g. steer axle70) that obstructs positioning on a hub. Inner ring202may have a diameter sized to accommodate steer axle70, hub odometer1410, oil level indicator1510, etc.

FIGS. 16C and 16Ddepict an exploded view of one embodiment of base assembly250showing bracket assembly1210, base1209, springs212, piston1214and alignment bushing1220, along with attachment hardware1205. In some embodiments, piston1214may not include any central spokes to accommodate steer axle70. Instead, piston1214may include partial spoke projections1232projecting radially inward some distance, leaving a large enough opening for components to pass. Spokes1232may be aligned with and positioned in channels1231to inhibit rotational movement of piston1214. In such embodiments, a plurality of springs1212or other resilient members may be positioned to contact piston1214and used to maintain an outward bias on piston1214and avoid binding by piston1214in base1209or alignment bushing1220. Operation of base assembly250may be similar to operation of base assembly250described above, in that tabs207on disk assembly1300may contact ribs1229on piston1214, piston1214may be depressed from a first biased position to a second biased position such that tabs207may be rotated some angle until tabs207align with notches1216in piston1214and are positioned behind radial arms1217, and tension on springs212may be released to allow piston1214to translate into a third biased position, locking tabs207(and thus disk assembly1300) relative to wheel assembly6.

An advantage to embodiments described herein may be the ability for the outer portion or edge of a disk assembly to maintain contact with a wheel. As depicted inFIGS. 2A-2B, 3A-3B, 16A and 16B, an outer edge or portion of disk assembly300or1300is maintained in contact with a rim of wheel assembly6. Maintaining contact at an outer edge may prevent undesirable effects associated with vehicle vibration and air streams in contact with disk300or310, such as noise or undue vibration, which may lessen any aerodynamic effect or undesirably wear components of the disk assembly300. An outer edge or portion of the disk may be reinforced or provided with pads, or otherwise configured to dampen vibration and reduce wear associated with contact with a rim of wheel assembly6.

Variations of various components may be possible without varying from the scope of the disclosure. For example,FIGS. 17A-17Cdepict views of alternative embodiments of base210.FIG. 17Adepicts a perspective view of one embodiment of base210having one extension227with channel237formed therein.FIG. 17Bdepicts a perspective view of one alternative embodiment of base210having a plurality of various shaped extensions227. Having different shaped extensions227may ensure that wheel cover assembly100is aligned in a particular orientation, enables locking, or some other advantage.FIG. 17Cdepicts a perspective view of one alternative embodiment of base210, with inner wall272having sides. As shown inFIG. 17C, inner wall272may have six sides. However, those skilled in the art will appreciate that more or fewer sides may be possible.