Abstract:
A method for producing a vehicle wheel and wheel cover assembly comprising the steps of: (a) providing a wheel cover having an inner surface and an outer surface; (b) selectively applying at least one shot of a first adhesive material to a portion of the inner surface of the wheel cover to define a predetermined masked area; (c) providing a vehicle wheel having an outboard face; (d) positioning the wheel cover and the vehicle wheel relative to one another whereby at least one cavity is formed between the inner surface of the wheel cover, the outboard face of the vehicle wheel, and the masked area of the wheel cover defined by the first adhesive material; and (e) selectively applying a second adhesive material to the cavity to secure the wheel cover to the vehicle wheel.

Description:
BACKGROUND OF THE INVENTION 
       [0001]    This invention relates in general to vehicle wheels and, in particular, to an improved vehicle wheel and wheel cover assembly and method for producing the same. 
         [0002]    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 also desirable that the cover is not easily discernible as separate from the wheel. It is 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. 
         [0003]    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. 
         [0004]    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 
       [0005]    This invention relates to a vehicle wheel and wheel cover assembly and method for producing the same. 
         [0006]    According to one embodiment, the method for producing a vehicle wheel and wheel cover assembly comprises the steps of: (a) providing a wheel cover having an inner surface and an outer surface; (b) selectively applying at least one shot of a first adhesive material to a portion of the inner surface of the wheel cover to define a predetermined masked area; (c) providing a vehicle wheel having an outboard face; (d) positioning the wheel cover and the vehicle wheel relative to one another whereby at least one cavity is formed between the inner surface of the wheel cover, the outboard face of the vehicle wheel, and the masked area of the wheel cover defined by the first adhesive material; and (e) selectively applying a second adhesive material to the cavity to secure the wheel cover to the vehicle wheel. 
         [0007]    According to another embodiment, the vehicle wheel and wheel cover assembly comprises: a vehicle wheel having an outboard face; and a wheel cover secured to the vehicle wheel, the wheel cover having an inner surface and an outer surface; wherein at least one shot of a first adhesive material is selectively applied to a portion of the inner surface of the wheel cover to define a predetermined masked area prior to selectively applying a second adhesive material to at least one cavity formed between the inner surface of the wheel cover, the outboard face of the vehicle wheel, and the masked area of the wheel cover defined by the first adhesive material to secure the wheel cover to the vehicle wheel. 
         [0008]    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 
         [0009]      FIG. 1  is a view of an embodiment of a vehicle wheel and wheel cover assembly. 
           [0010]      FIG. 2  is another view of the vehicle wheel and wheel cover assembly but showing only the first shot of the adhesive/foam material. 
           [0011]      FIG. 3  is a view of the wheel cover illustrated in  FIGS. 1 and 2 , showing the first shot of the adhesive/foam material applied to a portion thereof. 
           [0012]      FIG. 4  is an example of an embodiment of a sequence for producing the vehicle wheel and wheel cover assembly illustrated in  FIG. 1 . 
           [0013]      FIG. 5  is a schematic diagram illustrated an example of an embodiment of a first step of a process for producing a vehicle wheel and wheel cover assembly. 
           [0014]      FIG. 6  is a schematic diagram illustrating an example of an embodiment of a second step of a process for producing a vehicle wheel and wheel cover assembly. 
           [0015]      FIG. 7  is a view similar to  FIG. 3  showing an alternate embodiment of a first shot of an adhesive/foam material applied to a portion of the wheel cover. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0016]    Referring now to the drawings, there is illustrated in  FIGS. 1 and 2  a view of a vehicle wheel and cover assembly, indicated generally at  10 , including a first embodiment of a wheel cover retention system, indicated generally at  12 . As shown therein, the vehicle wheel and cover assembly  10  defines an axis X and includes a vehicle wheel, indicated generally at  22 , and a wheel cover, indicated generally at  30  which as will be discussed below, are secured together. The vehicle wheel  22  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. 
         [0017]    In the illustrated embodiment the vehicle wheel  22  of the vehicle wheel and cover assembly  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. 
         [0018]    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 A. 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  FIG. 1 ). The lug bolt receiving holes  18 B are adapted to receive lug bolts (not shown) and nuts (not shown) for securing the vehicle wheel  22  on an axle (not shown) of a vehicle. Also, as shown in this embodiment, the wheel disc  16  further includes a plurality of windows or openings  24  formed therein between each pair of spokes  26 . In the illustrated embodiment, the wheel disc  16  includes five window  20 , only one of such windows  20  illustrated in  FIG. 1  and two of such windows  20  illustrated in  FIG. 2  and five spokes  26 , only one of such spokes  26  illustrated in  FIG. 1 . Alternatively, the construction, material and/or make-up of the wheel disc  16  may be other than illustrated if so desired. 
         [0019]    In the illustrated embodiment, the wheel cover retention system  12  includes the wheel cover  30  which is secured to the vehicle wheel  22 . As will be discussed below, the wheel cover retention system  12  utilizes multiple “shots” of a suitable material, i.e., an adhesive/foam material, dispensed preferably prior to the assembly of the wheel cover  30  and the vehicle wheel  22  and/or after the assembly of the wheel cover  30  and the vehicle wheel  22 . This will allow masking tools to effectively “shut off” areas of the wheel cover  30  and vehicle wheel  22  prior to assembly that are not accessible otherwise. 
         [0020]    In the illustrated embodiment, the wheel cover  30  is preferably 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 (two or more pieces) wheel cover formed of like or unlike materials if so desired. 
         [0021]    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. In the illustrated embodiment, the wheel cover  30  includes an inner surface  30 A which has portions which generally conform to the outboard face  22 A of the wheel  22  and portions which are spaced apart from the outboard face  22 A of the wheel  22 . 
         [0022]    Also, as best shown in  FIG. 3 , the wheel cover  30  includes a center hub hole  32 , a plurality of lug bolt openings  34 , a plurality of window  36 , and a spoke  38  provided between each pair of the windows  36 . The center hub hole  32  of the wheel cover  30  is preferably adapted to be coaxial with the axis X of the wheel  10  and the center hub hole  18 A. The lug bolt openings  34  of the wheel cover  30  are preferably adapted to be coaxial with lug bolt holes  18 B of the wheel  22 . The windows  36  of the wheel cover  30  generally correspond to or resemble the windows  20  provided in the wheel  22 . The spokes  38  of the wheel cover  30  preferably cover the spokes  26  of the wheel  22  and preferably impart a desired styling to the vehicle wheel  22 . Alternatively, the construction, material and/or make-up of the wheel cover  30  may be other than illustrated if so desired. 
         [0023]    Referring now to  FIG. 4 , there is illustrated a block diagram illustrating a preferred sequence of steps for producing the first embodiment of the vehicle wheel and cover assembly  10 . As shown therein, in step  40  and as illustrated schematically in  FIG. 5 , the wheel cover  30  is placed face-down onto a lower masking tool (the lower masking tool shown schematically in  FIG. 5  by reference number  60 ), such that the lower masking tool  60  is preferably adjacent the outer surface  30 B of the wheel cover  30 . As will be discussed below, the lower masking tool  60  is operative to support and locate the wheel cover  30  and prevent a selected adhesive/foam material from contacting the outer “decorative” surface  30 B of the wheel cover  30 . Also, in step  40 , a pre-form tool (shown schematically in  FIG. 5  and identified by reference number  62 ) for the first “shot” of a selected adhesive/foam material is located on the wheel cover  30  preferably adjacent the inner surface  30 A thereof and all three parts (the lower masking tool  60 , the wheel cover  30 , and the pre-form tool  62 ) are located and clamped together as an assembly as shown schematically in  FIG. 5  in step  40 . 
         [0024]    Next, in step  42 , the assembly is preferably allowed to reach a desired controlled temperature (either by external or internal, heating or cooling) and then a suitable adhesive/foam material  54  is selectively dispensed into one or more cavities (one of such cavities shown in phantom in  FIG. 5  by reference number  56  defined between the pre-form tool  62  and the wheel cover  30 , and the adhesive/foam material  54  is allowed to react. Depending upon the particular adhesive/foam material  54  which is used, step  42  may not require any heating or cooling but may take place at room temperature. 
         [0025]    After a desired period of time, next in step  44 , the pre-form tool  62  is unclamped and the wheel cover  10  is removed having the first shot of the adhesive/foam material  54  selectively adhered thereon in a desired “masking pattern”, such as shown for example in the masking pattern shown in the embodiment illustrated in  FIGS. 2 and 3 . As shown in this embodiment, the adhesive/foam material  54  is preferably generally deposited about an inner circumferential portion of the inner surface  30 A of the wheel cover  30 . More preferably, the first shot of the adhesive/foam material  54  is selectively adhered around the center hub hole  32  and the lug bolt openings  34  of the wheel cover  30 . Alternatively, it is possible that the wheel cover  30  may receive more than one shot or dose of the same or different adhesive/foam materials involving the use of one or multiple pre-form tools depending on the desired masking effect which is to be achieved and/or that the particular areas of the wheel cover  30  which receive the adhesive/foam material may be other than illustrated if so desired. For example, as shown in  FIG. 7 , step  42  may be operative to deposit an adhesive/foam material  70  on the inner surface of the wheel cover  30  around the lug bolt openings  34 . Thus, it can be seen that one or more desired area or areas of the wheel cover  30  may be operatively masked by the selective application of the adhesive/foam material(s) during step  42 . 
         [0026]    Following this, in step  46 , the lower masking tool  60  from the step  42  may be used if desired. In this case, in step  44  as illustrated schematically in  FIG. 6 , the wheel cover  30  would remain on the lower masking tool  60  and the vehicle wheel  22  is assembled face-down on top of the wheel cover  10 , such that the outboard surface  22 A of the wheel  22  is preferably adjacent the inner surface  30 A of the wheel cover  30 . A brake or back side  22 B of the vehicle wheel  22  is masked using an upper masking tool (schematically shown in  FIG. 6  and identified by reference character  64 ). The four parts (the lower masking tool  60 , the wheel cover  30 , the vehicle wheel  22  and the upper masking tool  64 ) are clamped together and preferably allowed to reach a desired controlled temperature (either by external or internal, heating or cooling). Depending upon the particular adhesive/foam material which is used in the next step, step  48  may not require any heating or cooling but may take place at room temperature. 
         [0027]    Next, in step  48 , a suitable adhesive/foam material (shown in  FIG. 1  by reference number  58 ) is dispensed into one or more cavity areas defined between the cover  30  and the wheel  10  and allowed to react (for discussion purposes, one of such cavity areas indicated by reference number  66  in  FIG. 2  and one of such cavity areas also shown in phantom in  FIG. 6  by reference number  66 ). During step  48 , the areas between the wheel cover  10  and the vehicle wheel  22  that are not masked properly by the upper and lower mask tools  64  and  60 , respectively, are preferably already sealed and filled by the pre-foam shot(s) of material  54  in prior step  42  and thus simplify the upper and lower mask tools  64  and  60 , respectively, by eliminating areas of negative draft and removing core-out members and their respective actuators. 
         [0028]    Preferably, during step  48 , all the cavity areas between the wheel cover  30  and the vehicle wheel  22  are filled with the suitable adhesive/foam material  58 ; however, if desired, only some of the such cavity areas may be filled during step  48  if so desired. Following this, in step  50 , preferably after a desired period of time, the upper mask tool  64  is unclamped and removed and the wheel assembly  10  is removed and packaged for shipment. During storage and shipment the adhesive/foam material(s)  54  and/or  58  is (are) allowed to cure and attain full strength and excess inventory is reduced. Preferably, the adhesive/foam material  58  that fills the cavity areas during step  48  permanently secures the wheel cover  30  to the vehicle wheel  22 . Alternatively, other means, such as mechanical retention means, i.e., snap tabs, fasteners and the like (not shown), may be used to assist in positioning the wheel cover  30  relative to the vehicle wheel  22  and/or for permanently securing the wheel cover  30  to the vehicle wheel  2  if so desired. 
         [0029]    Alternatively, the method for producing the vehicle wheel and cover assembly  10  may be other than illustrated if so desired. For example, the shot or shots of the adhesive/foam material(s) may be of the same or differing products. Each shot may be and masking tools may be heated and/or cooled as necessary at any time during the process. The timing between shots can be varied depending on the desired performance of the assembly such as seam lines, cohesive bond strength, appearance and manufacturing considerations. Finally, while the embodiments are illustrated for use in producing a vehicle wheel and cover assembly, it is envisioned that this method may be used in connection with other automotive and non-automotive parts that are joined by an adhesive/foam material (whether expanding foam or other product) and is not easily masked as an assembly. Also, while the first shot of the adhesive/foam material  54  in step  42  is preferably formed directly on the inner surface of the wheel cover to be used, it may be separately formed and secured to the inner surface of the wheel cover by suitable means, such as an adhesive, prior to application of the adhesive/foam material  58  in step  48  or it may be separately formed and secured and/or maintained (i.e., if used as an “insert” masking member which may or may not be secured in place), by the application of the adhesive/foam material  58  in step  48 . 
         [0030]    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.