Abstract:
A brake cover and a process for using the brake cover are disclosed. The brake cover comprises a circular plate having a front surface, a back surface, a perimeter, a centrally located axle hole, and a plurality of lug holes surrounding the axle hole, and a sidewall integrally formed along the perimeter of the circular plate and projecting from the circular plate at a selected angle relative to a plane defined by the circular plate. The process comprises mounting the brake cover on a hub and an axle of the vehicle, the brake cover being designed to cover the brake components, mounting a wheel on the hub and axle of the vehicle, such that the brake cover is sandwiched between the wheel and the hub, and securing the wheel onto the hub.

Description:
FIELD OF THE INVENTION 
     This invention relates to brake covers adapted for use with automobile wheels, and in particular to brake covers which improve appearance and reduce the accumulation of harmful brake dust on alloy wheels. 
     BACKGROUND 
     Automobile wheels come in two basic kinds: steel wheels and alloy wheels. Steel wheels are standard equipment for cars, because they are inexpensive. Unfortunately, steel wheel are utilitarian in appearance and use, and are often covered with hub caps to disguise their utilitarian appearance. Alloy wheels are usually not offered as standard equipment because they are expensive, so if car owners want to improve the appearance of their cars, they must buy alloy wheels from the car dealer or from after-market sellers. In addition to their functional use as wheels, alloy wheels dramatically improve the vehicle&#39;s appearance. 
     Despite their improvement of a vehicle&#39;s appearance, alloy wheels suffer from a couple of problems. First, alloy wheels typically have large open vents. The open vent designs allow for more intricate wheel styles, but they also allow unsightly brake mechanisms to be seen through the alloy wheel, including the brake drums, brake discs and overall braking mechanisms. Depending upon the vehicle, some use brake drums and others use disc brakes. Through daily use, braking mechanisms often have rust on their surfaces. This rust does not impair the vehicles ability to reduce speed, however, the rusty brake drums and discs are not attractive when seen through the open vents of an alloy wheel. Since consumers purchase alloy wheels mainly for their cosmetic looks, visibility of the unsightly rusty brake drums and discs defeats the purpose of the alloy wheels. 
     Second, braking mechanisms such as disc brakes create significant amounts of brake dust. Brake dust is corrosive and can damage the finish of an alloy wheel, which is both unsightly and damaging to alloy wheels if not washed away frequently. Although brake dust will cover both steel and alloy wheels, it is more of a problem with alloy wheels. Gradually over many years, the alloy wheel finish may become pitted or dull from the brake dust&#39;s corrosive nature. Since alloy wheels are expensive relative to steel wheels, consumers do not want brake dust damaging their alloy wheels. Additionally, the brake dust makes the alloy wheels look dirty. Through the course of daily driving, a vehicle and its wheels will become dirty from the dirt and grime found on roads. However, the brake dust significantly exacerbates the appearance of dirt on the alloy wheel. 
     SUMMARY OF THE INVENTION 
     A brake cover and a process for using the brake cover are disclosed. The brake cover comprises a circular plate having a front surface, a back surface, a perimeter, a centrally located axle hole, and a plurality of lug holes surrounding the axle hole, and a sidewall integrally formed along the perimeter of the circular plate and projecting from the circular plate at a selected angle relative to a plane defined by the circular plate. The process comprises mounting the brake cover on a hub and an axle of the vehicle, the brake cover being designed to cover the brake components, mounting a wheel on the hub and axle of the vehicle, such that the brake cover is sandwiched between the wheel and the hub, and securing the wheel onto the hub. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a perspective view of a first embodiment of the inventive brake cover. 
     FIG. 2 is a front view of the embodiment shown in FIG.  1 . 
     FIG. 3 is a side view of the embodiment shown in FIG.  1 . 
     FIG. 4 is a flow chart of the process used to manufacture the brake cover shown in FIG.  1 . 
     FIG. 5 illustrates the spinning step in the manufacturing of the brake cover of FIG.  1 . 
     FIG. 6 illustrates the spinning step in the manufacturing of the brake cover of FIG.  1 . 
     FIG. 7 is a perspective view of a second embodiment of the inventive brake cover. 
     FIG. 8 is a front view of the inventive brake cover of FIG.  7 . 
     FIG. 9 is a sectional view of the of the embodiment shown in FIG.  7 . 
     FIG. 10 is a cross-sectional view of a third embodiment of the present invention. 
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Described below are three embodiments of the present invention. The embodiments illustrate ways in which the present invention can be implemented. In the description that follows, like numerals represent like elements in all figures. For example, where the numeral  10  is used to refer to a particular element in one figure, the numeral  10  appearing in any other figure refers to the same element. 
     First Embodiment 
     FIG. 1 shows a first embodiment of the present brake cover suitable for use with drum brakes, also referred to as a “brake drum cover.” The brake cover  10  is generally pan-shaped and comprises a substantially flat, circular plate  12  having a sidewall  14  integrally connected to, and extending completely around, the perimeter of the plate. The entire brake cover  10  is a single piece of metal. The circular plate  12  has front surface  16  and a back surface  18  (see FIG.  3 ). An axle hole  22  is positioned in the center of the plate  12 , and a plurality of lug holes  24  are positioned around the axle hole. The cover  10  is preferably made from T-5054 grade aluminum. Other metals may be used as well, but aluminum&#39;s heat transfer characteristics make it ideally suited for this application. 
     FIG. 2 illustrates the size and position of the axle hole and lug holes on the front surface of the brake cover. The diameter of the cover  10  along the rim of the sidewall  14  varies between 11 and 13¾ inches, and the diameter of the plate  12  varies between 9⅝ and 11½ inches, although either of these dimensions can be altered to suit the application. The axle hole  22  is centered on the plate  12 , and usually has a diameter between 2¾ and 3{fraction (7/16)} inches, with a preferred diameter of 3½ inches, although its exact diameter will depend on the particular vehicle on which the cover is used. Preferably, the axle hole  22  is slightly oversized to compensate for a variety of vehicle axle sizes. 
     The pattern of the lug holes  24 , and their respective sizes, are also determined by the vehicle on which the brake cover  10  is used. Since the brake cover is secured to the vehicle&#39;s axle and hub by the lugs, the pattern of the lug holes  24  must correspond to the pattern of the lugs. Vehicles may use 4, 5, 6, 7 or 8 lugs to secure their wheels to the axle. The lug holes  24  are positioned along a circle having a diameter matching the diameter of the vehicle lug pattern. Typical bolt pattern diameters are between 4.5 and 8 inches, as well as between 80 mm and 135 mm. Again, these bolt pattern diameters may vary according the bolt pattern of new vehicles. 
     FIG. 3 is a side view showing the sidewall attached around the perimeter of the plate  12  and projecting from a plane defined by plate. The sidewall  14  is integrally connected to the perimeter of the plate portion, and projects toward the back surface of the plate at a selected angle a relative to a plane defined by the plate  12 . The angle α is typically between 82 and 85 degrees, but may range between 60 and 85 degrees. The distance t between the plate  12  and the rim  15  of the sidewall is preferably about 3⅞ inches. As further discussed below, the sidewall  14  is formed by bending the perimeter of a round blank in a direction normal to the back surface  18  of the plate. 
     FIG. 4 illustrates the steps in the process for making the cover  10 . At step  30 , aluminum sheets {fraction (1/16)} inches thick are sheared into circular blanks having a diameter between 14¾ and 21¼ inches, depending on the application. At step  32 , the axle hole  22  and lug holes  24  are punched into the blanks using a die with cutting keys matching various vehicle bolt patterns. A five-bolt pattern is illustrated in FIGS. 1 and 2, although bolt patterns may have 4, 5, 6, 7 or 8 holes. The cutting keys typically have diameters between 12 mm and {fraction (9/16)} inch, but as new vehicles are manufactured, the number of cutting keys and the cutting key diameters may be adjusted to reflect the bolt patterns and sizes of new vehicles. Once all the holes are punched in the plate at step  32 , they are de-burred at step  34  to eliminate any sharp edges that may cut someone handling the product. Following de-burring, the blank is shaped into a brake cover at step  36  by a process known as spinning. 
     FIGS. 5 and 6 together illustrate the spinning process of step  36 . In FIG. 5, a steel chuck  46  is created in the shape and size of the brake cover and the top surface  47  of the chuck is brought into contact with the back surface  50  of the blank  48 . In FIG. 6, the blank and chuck are loaded onto a spinning machine whereby the blank is bent to conform to the shape of the chuck by a roller  52 . The roller  52  rolls around the sloped surface  47  of the chuck, bending the perimeter of the blank into contact with the sloped surface  47 . Different sized chucks are needed for various brake drum or disc brake applications. 
     During spinning, a texture may optionally be applied to the front surface of the cover  10  at step  38  by manually pressing a scoring pad into the outside surface and applying approximately 10-13 pounds of pressure. The scoring starts from the center and the pad in drawn across the surface to the outside edge. The aluminum is soft and easily accepts the texture, which will be a circular pattern with a pleasing aesthetic appearance. Once the cover is shaped and textured, it is cleaned at step  40  to remove any oil, dirt and metal shavings left behind during manufacture. Any cleaning method can be used, as long as the cover is free of oil, dirt and metal shavings upon completion so that the finish can be applied. 
     Once the cover is cleaned, the final step is to apply the finish, either by powder coating at step  42  or by polishing at step  44 . The powder coating may be colored or clear. If colored powder coats including, but not limited to, black, red, blue and white are used, the optional texturing in step  38  is not needed because the colored powder coat covers the texture anyway. If a clear powder coat is used, the texture in step  38  will show through the clear powder coat. The polished finish of step  44  may be performed by any metal polishing process capable of polishing the metal to a high, mirror-like finish. 
     In operation of the brake cover  10 , a vehicle&#39;s alloy wheel is removed by disengaging the lug nuts and lifting the wheel off of the wheel hub at the end of the axle. The proper sized brake drum cover or disc shield is positioned on the hub with its back surface toward the braking mechanism, such that the axle projects through the axle hole  22  and the lugs project through the lug holes  24 . The front surface  16  of the cover faces outward. The alloy wheel is then positioned on the axle such that the cover is sandwiched between the brake mechanism. The lug nuts are then put on the lugs and tightened to keep the wheel on the vehicle. 
     Second Embodiment 
     FIG. 7 illustrates a second embodiment of the brake cover  60  suitable for use with disc brakes. These are also known as “disc shields.” The brake cover  60  is flatter than the brake cover  10 , and comprises a substantially flat, circular plate  62  having a shallow sidewall  64  integrally connected to, and extending completely around, the perimeter of the plate. A depression  66  is centered on the plate. The circular plate  62  has a front surface  61  and a back surface  63  (see FIG.  9 ). An axle hole  68  and a plurality of lug holes  70  are offset from the center of the plate. The cover  60  is a single piece of metal, preferably T-5054 grade aluminum. Other metals may be used as well, but aluminum&#39;s heat transfer characteristics make it ideally suited for this application. 
     FIG. 8 illustrates the size and position of the depression, axle hole and lug holes on the front surface of the brake cover. The cover  60  preferably has an overall diameter of about 13{fraction (11/16)} inches, and the depression preferably has a diameter of about 8{fraction (3/16)} inches, although both these dimensions can be varied to fit the application. The size of the axle hole and lug holes is similar to that described above in connection with the brake cover  10 . The hole center  74  represents the center of the axle hole  68  as well as the center of a circle drawn through the centers of the lug holes  70  (i.e. the centroid of the lug holes). This hole center  74  is offset from the true center  72  of the cover  60  by a distance x. The offset distance x, typically about {fraction (1/16)} of an inch, causes the cover  60  to rotate eccentrically when attached to the hub, thus creating a slight vortex effect which helps blow brake dust away from the alloy wheels. 
     FIG. 9 is a side view showing the sidewall attached around the perimeter of the plate  62  and the depression  66  at the center of the plate. The sidewall  14  is integrally connected to the perimeter of the plate portion, and projects toward the back surface of the plate at a selected angle β relative to a plane defined by the plate  12 ; the angle β is typically between 82 and 85 degrees, but may range between 60 and 85 degrees. The distance t between the plate  62  and the rim  15  of the sidewall is preferably about ⅜ of an inch, while the distance s between the front surface  61  and the bottom  67  of the depression is about {fraction (7/16)} inch. When the cover  60  is installed, this difference between t and s results in a small gap between the rim  65  of the cover and the brake disc. As with the cover  10 , the sidewall  64  of the cover  60  is formed by bending the perimeter of a round blank in a direction normal to the back surface  63  of the plate. 
     The depression  66  is necessary so that the portions of the plate outside the depression will not contact the disc brakes when the cover  60  is installed. The depression  66  preferably has a diameter of about 8{fraction (3/16)} inches, and a depth of about {fraction (7/16)} inches. When not installed, the bottom  67  of the depression is cambered, preferably with a camber of about {fraction (1/32)} of an inch. The dotted line A illustrates the cambered bottom. When the cover is installed, most of the camber disappears, although a slight amount of bending is caused in the cover  60 . 
     The brake cover  60  is manufactured using the process of FIG. 4, with the addition of a step to press the depression  66  into the plate and except for offsetting the axle hole and lug holes from the center of the plate. The chuck used to spin the brake cover  60  has a different top surface  47  (FIG. 6) to accommodate the depression in the cover. The brake cover  60  is used in exactly the same way as the brake cover  10 . 
     Third Embodiment 
     FIG. 10 illustrates a third embodiment of the brake cover which is a hybrid of the covers  10  and  60 . The third embodiment has the overall shape and size of the cover  10  (FIG.  1 ), except that the flat plate  12  takes on the depression  76  similar to the depression  66  found in the flat plate  62  of the cover  60  (FIG.  8 ). 
     The present brake covers  10  and  60 , when made and used as described, have some important advantages. First, the brake cover improves the appearance of alloy wheels. The cover is placed between the brake drums/disc brakes and the alloy wheels, obscuring the braking mechanism from sight so that the braking mechanism may not be seen through the vents of the alloy wheel. The overall appearance of the alloy wheel is dramatically improved. The powder coated or polished finish on the brake drum covers or disc shields makes a consistent background to showcase the alloy wheel, and the wheel has a finished and more aesthetically pleasing appearance because the braking mechanism is no longer visible. 
     Second, the brake cover  60  prevents brake dust from getting on the alloy wheels by covering the brakes and blowing the dust inward toward the vehicles. The shape of the covers provides a barrier between the brakes and the alloy wheels, so the brake dust must get through the brake cover/shields to reach the wheels. Additionally, the cover  60  has an offset from center, which creates a slight vortex or pinwheel effect. The pinwheel effect creates an air flow which gently pushes the dust away from the wheels toward the vehicle. As it blows inward rather than outward, the dust falls to the road and does not come to rest on the alloy wheels. 
     Three embodiments of the present invention have been described. A person skilled in the art, however, will recognize that many other embodiments are possible within the scope of the invention. For this reason, the scope of the invention is not to be determined from the description of the embodiments, but must instead be determined solely from the following claims.