Patent Publication Number: US-2016221388-A1

Title: Wheel cover retention system

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application claims benefit under 35 USC section 119(e) of U.S. Provisional Application Ser. No. 62/109,137, filed Jan. 29, 2015, entitled WHEEL COVER RETENTION SYSTEM, the entire contents of which are incorporated herein by reference. 
    
    
     BACKGROUND 
     The present invention relates to wheel cover retention systems, and more particularly relates to a wheel cover retention system having wire retainers holding a wheel cover on a wheel rim. The system is particularly effective for aerodynamic wheel covers applied to semi-tractor and semi-trailer wheels, but is not limited to only that application. 
     Fuel is a major expense in the trucking industry, and items to improve miles per gallon, even a small amount, can be very important. Recently, it was discovered that reducing air turbulence around truck wheel rims is a surprisingly good way to improve gas mileage. However, any wheel-mounted device must be durable enough to withstand the harsh environment experienced by truck wheels, including impacts by stones and road debris, abrasion by ice and dirt, harsh treatment from adverse weather conditions, and must withstand the overall difficult environment seen by wheels at road level. Also, any such item preferably should have a good appearance, provide a quick and secure installation, preferably include a minimum of parts, and be competitive in manufacturing and installation cost. Also, it is desirable that any such item be relatively light weight and easy to ship in a compact, low volume container, so that they can be shipped to remote locations at minimal cost. These conflicting requirements have made it difficult to arrive at an optimal solution. 
     SUMMARY OF THE PRESENT INVENTION 
     In one aspect of the present invention, a wheel cover retention system for holding a wheel cover on a wheel rim, comprises a plurality of bent wire retainers having a first end connector adapted to releasably engage an opening in the wheel rim and a second end connector adapted to engage and hold the wheel cover on the wheel rim in a position centered on the wheel rim. 
     In another aspect of the present invention, an aerodynamic covered wheel apparatus comprises a wheel rim; a wheel cover shaped to engage and aerodynamically cover an outside of the wheel rim; and a plurality of separate elongated retainers securing the wheel cover to the wheel rim. 
     In another aspect of the present invention, an aerodynamic covered wheel apparatus comprises wheel rim having a hub for mounting to an axle and having air-passing openings in the hub around the axle; a wheel cover shaped to engage and aerodynamically cover an outside of the wheel rim; and a plurality of retainers securing the wheel cover to the wheel rim, the retainers engaging the openings and engaging the wheel cover. 
     In another aspect of the present invention, a method of retaining an aerodynamic cover to a wheel rim comprises providing the wheel rim with air-passing openings; providing a wheel cover shaped to engage and aerodynamically cover an outside of the wheel rim; providing a plurality of retainers; and securing the wheel cover to the wheel rim using retainers extending between selected of the air-passing openings and the wheel cover. 
     These and other aspects, objects, and features of the present invention will be understood and appreciated by those skilled in the art upon studying the following specification, claims, and appended drawings. 
    
    
     
       BRIEF DESCRIPTION OF DRAWINGS 
         FIG. 1  is a side view of a rear portion of a semi-trailer with two wheels, the left illustrated one wheel being covered by the present wheel cover system, and the right illustrated one wheel not covered. 
         FIG. 2  is an exploded perspective view showing the rim and wheel cover and retainer(s) of the left illustrated covered wheel in  FIG. 1 . 
         FIGS. 3-4  are perspective views showing one of the bent wire retainers shown in  FIG. 2 ,  FIG. 3  showing the retainer in an installed open position, and  FIG. 4  showing the retainer in a closed ready-to-install position. 
         FIG. 5  is a perspective view showing one bent wire retainer attached to and extending laterally from the wheel cover of  FIG. 2 , the retainer being in an installed position but without the wheel rim being shown. 
         FIG. 6  is a fragmentary view showing one bent wire retainer attached to and extending laterally from the wheel cover of  FIG. 2 , the retainer being in an installed position but only showing part of the wheel cover and part of the wheel rim. 
         FIG. 7  is an axial cross section showing the wheel rim, wheel cover, and one retainer of  FIG. 6 , the wheel rim having a relatively larger air-passing opening as compared to  FIG. 10 . 
         FIG. 8  is a cross section taken along line VIII-VIII in  FIG. 7 . 
         FIG. 9  is an axial cross section similar to  FIG. 6  but showing a different wheel rim, a same wheel cover, and a same one retainer, the wheel rim having a relatively smaller air-passing opening as compared to the wheel rim in  FIG. 6 . 
         FIG. 10  is an axial cross section showing the wheel rim, wheel cover, and one retainer of  FIG. 9 , the wheel rim having a relatively smaller air-passing opening as compared to  FIG. 7 . 
         FIG. 11  is a cross section taken along line XI-XI in  FIG. 10   
         FIG. 12  is a cross-sectional view similar to  FIG. 10  but showing the snap-end of the retainer with a different orientation than the snap-end of the retainer in  FIG. 10 . 
     
    
    
     DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS 
     A wheel cover retention system  40  ( FIGS. 1-2 ) is provided for holding an aerodynamic wheel cover  41  on a wheel rim  20 . The system  40  includes a plurality of bent wire retainers  42  (such as 5 or more), each having a resilient first end connector  43  that snaps into an air-passing opening  21  in the wheel rim  20  and a hook-shaped second end connector  44  that hooks through a flanged hole in the wheel cover  41 . When engaged, the retainers  42  hold the wheel cover  41  on the wheel rim  20  in a position centered on the wheel rim  20 . An exterior surface of the wheel cover  41  defines a relatively flat dome-shaped surface having an aerodynamic disc-like shape, which reduces air turbulence and thus leads to improved gas mileage. A large hole in a center of the wheel cover  41  provides access into the truck&#39;s associated axle and wheel rim  20  (and to the retainers  42  for installing the retainers  42 ). The present wheel cover retention system  40  is particularly useful for semi-trailer and semi-tractor wheels (aluminum or steel), because commercial wheels for semi-trucks and trailers include a relatively deep recess that generate a lot of air turbulence. Our testing shows that the present wheel covers  41  can increase miles per gallon of a semi-trailer by a significant amount via reducing wind resistance during transit. However, it is contemplated that the present innovative concepts are not limited to just semis, but instead can be used in many other wheel arrangements. 
     The illustrated rim  20  ( FIG. 7 ) carries an inflated truck tire  22  sealed to and carried by a recess defined by its rim edge  23 . The tire  22  includes a sidewall  22 ′ sealed on the rim edge  23  and includes tread  22 ″. The rim  20  includes a hub  24  that fits around and is secured to an end of an axle  25 . Studs and nuts  26  retain the rim  20  on the axle  25 . Air passing openings  21  are spaced radially outwardly from the hub  24  and circumferentially around the rim  20  to reduce a weight of the rim, and also permit air pass-through. The lateral distance from the hub  24  (and also from the openings  21 ) to an outer surface of the rim edge  23  of the rim  20  is a known dimension for a given style of rim  20 . It is noted that the distance may vary for different style rims  20 , and also a size and shape of the openings  21  in the rim  20  may vary from one rim style to another. Some rims  20  are steel and have relatively smaller air-passing openings  21 , while other rims  20  are aluminum and have larger (or smaller) air-passing openings  21 . Both openings  21  reduce weight and save material cost, as well as to provide some air movement around the axle  25 , such as for cooling brakes. 
     The illustrated retainer  42  is shown in  FIGS. 3-4 , and its installation is shown in  FIGS. 5-8 . As noted above, the illustrated retainer  42  ( FIGS. 3-4 ) includes a resilient first end connector  43  (called a “snap connector” herein) and a hook-shaped second end connector  44  (called a “hook connector” herein) joined by an elongated linear wire section  45  (called a “tether section” or “shank” herein). The snap connector  43  includes a tether-side rim-engaging wire section  50 , a free-end rim-engaging wire section  51 , and a resilient wire section  52  joining the sections  50 ,  51 . The resilient wire section  52  defines a generally pointed or “bullet” shape configured to guide the snap connector  43  into and through a selected opening  21  in the rim  20 . The tether-side wire section  50  includes a step  53  ( FIG. 3 ) shaped to engage an outer surface of the rim  20  when the retainer  42  is installed in an air-passing opening  21  ( FIG. 8 ). The free end rim-engaging wire section  51  includes three steps  54 - 56  ( FIG. 3 ). The two steps  55 - 56  nearest an end of the bent wire forming the retainer  20  engage opposing surfaces of the rim  20  when the retainer  42  is installed in an air-passing opening  21  ( FIG. 8 ). Notably, the outermost step  56  allows the snap connector  43  to be held in a closed pre-installation position ( FIG. 4 ) to facilitate extending the snap connector  43  through a selected air-passing opening  21 . After being positioned within an air-passing opening  21 , the installer can then slip open the snap connector  43  to engage the rim  20  as shown in  FIG. 8 . The hook connector  44  ( FIG. 5 ) is attached to a hole flange in the wheel cover  41  as discussed below. 
     The wheel cover  40  ( FIG. 5 ) includes a disc-shaped body  70  with centered access opening and (if desired) a mating semi-flat center cover  72  that closes the access opening in its center. The center cover  72  ( FIG. 2 ) can be attached by different means. The illustrated center cover  72  includes an annular flange  73  with tabs  74  that mates against an annular flange  75  on the wheel cover body  70 , with the tabs  74  slipping past the flange  75  such that rotation of the center cover  72  secures the center cover  72  to the wheel cover  72 . Detents (not shown) can be used to fix the center cover  72  in its installed rotated position. Advantageously, the center cover  72  can be used to provide different logos and appearances, while allowing the body  70  to stay the same. Nonetheless, it is contemplated that the body  70  can be coated, painted, textured, or otherwise treated to provide many different looks, all while maintaining a same shape of the body  70  to minimize tooling costs. 
     The body  70  of the wheel cover  72  ( FIG. 5 ) is sloped for optimal aerodynamics, and also includes a plurality of ribs to maintain its shape and to provide structure for attaching the retainers  42 . Different rib arrangements can be used, depending on functional requirements of a particular installation, and depending on molding requirements desired by the provider of the wheel covers  41 . The illustrated ribs include an inside annular rib  80  that extends around the center access opening. Integrally-formed flanges  81  extend from the inside annular rib  80 , and include holes  82  for receiving the hook connector  44  of the retainer  40 . Radial ribs  83  extend from the inside annular rib  80  to a first outer rib  84 . The illustrated first outer rib  84  extends circumferentially, but is discontinuous. It is contemplated that it could be a continuous single rib if desired. A second outer rib  85  extends parallel to and slightly radially outward from the first outer rib  84 . As shown in  FIG. 7 , a foam bulbous dampener  86  includes a pair of closely-spaced fingers  86 ′ shaped to grip the second outer rib  85 , and a bulbous (hollow) portion  87  shaped to abut an outer surface of the rim edge  23  and to abut an inner surface of the wheel cover  41 . This allows the dampener  85  to reduce noise and vibration and hence reduce any wear or noise due to relative movement between the wheel cover  41  and the rim  20 . It is noted that multiple dampeners can be used if desired, and/or the dampener can be mounted on either or both of the ribs  84 ,  85 . It is also noted that the snap connector  43  is bent in a  90  degree orientation to the hook connector  44 , which is best shown by comparing  FIGS. 7 and 8 . This positions the snap connector  43  so that it engages circumferentially-opposite ends of the air-passing opening  21 , thus providing a best engagement and best retention. 
     The present retainers  40  are designed to work on wheel rims  20  having a relatively larger air-passing opening  21  (see  FIGS. 7-8 ) as well as on wheel rims having a relatively smaller air-passing opening  21  (see  FIGS. 11-12 ). The engagement of the snap connector  43  to the wheel rim  20  with larger opening  21  is described above, and shown in  FIG. 8 . The engagement of the snap connector  43  to a wheel rim  20  with smaller opening  21  is shown in  FIG. 11 . As shown in  FIG. 11 , the step  54  combines with step  53  to engage opposing surfaces of the wheel rim  20  to secure the retainer  42  to the wheel rim  20 . This arrangement allows a single style retainer  42  to be used regardless of which style wheel rim  20  is used. 
     As shown in  FIG. 12 , the retainer  42  can be modified to position the snap connector  43  in a same orientation on the retainer  42  as the hook connector  44  if desired, instead of at  90  degrees as previously shown. 
     There are a variety of different wheel rims in the industry, but two main wheel rims predominate. In a first predominate wheel rim  20 , the opening  21  (see  FIG. 12 ) is smaller, such as 1-½″ in size. In a second predominate wheel rim, the opening  21  is larger (see  FIG. 8 ), such as 2-¾″. When the retainers  42  are engaged in the larger opening  21  ( FIG. 7 ), the shank  45  of the retainer  42  extends approximately a known dimension (i.e. about 8-½″) toward the wheel cover  41 . It is noted that the shank  45  can be made non-linear or bowed (or another shape) if desired. A non-linear shank  45  allows the shank  45  to flex and adjust lengthwise, providing some tension and adjustability for different circumstances, while still providing adequate retention strength for retainers  42  to hold the wheel cover  41  to a given wheel rim  20 . For example, where foam bulbous dampener  86  is eliminated, it may be important to provide the shank  45  with a shape permitting length-adjusting behavior. This can be done by forming the shank  45  into an arc, or forming a V into the shank that permits expansion, or forming a coiled spring arrangement along its length, each of which provide elongation and yet provide resiliency and strength for retention. 
     It is contemplated that the retainers  42  can be made from a variety of different materials. The illustrated retainers  42  are preferably made from stainless spring steel wire having a diameter of 0.078″. They are dipped in a protective polymeric or non-conductive coating on all areas that may engage an aluminum (or metal) rim  20  in order to prevent galvanic corrosion. The number of retainers used can vary as needed, but it is expected to be at least 5 or more (e.g. 5-8). 
     The wheel cover  41  ( FIG. 2 ) can be made of any structural material. The illustrated wheel cover  41  is a polymeric material such as ABS or other structural polymer, and can be painted or chromed or otherwise treated for aesthetics. 
     It is to be understood that variations and modifications can be made on the aforementioned structure without departing from the concepts of the present invention, and further it is to be understood that such concepts are intended to be covered by the following claims unless these claims by their language expressly state otherwise.