Abstract:
An apparatus and method for securing a wheel to an axle that is particularly useful when the axle has fractured. The apparatus connects to the axle, for example at the axle flange, and also connects to the wheel hub assembly. A stabilizer contacts the axle conferring extra strength and stability to the apparatus, for example by extending inside of the hollow fractured axle. A reinforcement member can optionally be used to more firmly secure the apparatus to the axle. Methods for using the apparatus are also provided.

Description:
BACKGROUND 
     A. Field of the Disclosure 
     The field of the disclosure is automotive parts and repair. 
     B. Background of the Art 
     A fractured axle is a catastrophic failure in a wheeled vehicle. Upon fracturing, the axle will no longer support the weight of the vehicle. Typically the wheel will detach from the vehicle, and the portion of the vehicle that was supported by the wheel and the axle will fall until the chassis rests on the ground. The vehicle cannot be moved so long as the chassis rests on the ground. Attempts to do so will damage the chassis and be hindered by the enormous resistance posed by essentially dragging a portion of the vehicle&#39;s weight. 
     Several events can cause an axle to fracture. Inadequate lubrication of the axle of any wheeled vehicle can result in excessive wear leading to the axle failure. Off-road vehicles commonly operate on uneven ground which causes great stress to the axle; under such off-road conditions, even a well-maintained axle may fracture. Vehicles are often operated off-road in areas remote from service facilities and with poor communication infrastructure. Off-road vehicles are also operated during rescue missions and combat missions, in which it is not acceptable to wait for the vehicle to be towed to a service facility, and in which it is of dire importance that the mission continue despite mechanical failures. For these and other reasons, a means to effect a field repair of a fractured axle is desirable. 
     There is a long-felt but unmet need in the art for an adequate means to affix a wheel to a vehicle after the vehicle&#39;s axle has fractured. Previous solutions to this problem are insufficient in that they result in the newly affixed wheel frequently falling off the vehicle, requiring that the vehicle halt and the wheel be replaced on the vehicle. Thus there is a long-felt but unmet need in the art for a more lasting way to attach the wheel. Previous solutions also frequently require placement of some bracket or securing means on the outside of the vehicle to prevent (or merely delay) the wheel from falling off. Such brackets can damage the vehicle body and often snag objects in the vicinity of the vehicle. If the bracket is snagged, it may hinder the vehicle or pull off the bracket. Once the bracket is pulled off, the wheel falls off. Thus there is a long-felt but unmet need in the art for a way to attach the wheel to the vehicle that does not attach to the exterior of the vehicle. 
     SUMMARY 
     Disclosed is a superior and novel means for attaching a wheel to a vehicle that can be performed when an axle has fractured. An apparatus and method are provided for achieving the desired result. One of the objects of some embodiments of the method and apparatus is to allow the wheel to be attached quickly and easily under potentially adverse circumstances. Another object of some embodiments is to allow a standard wheel hub to be attached to the vehicle, such that no special hub or tire needs to be carried with the vehicle. Another object of some embodiments is to provide a strong, stable attachment that will be secure for long periods of time over rough terrain and at high speeds. 
     These and other objects are achieved by an apparatus comprising a hub assembly fastening point, an axle fastening point, and a stabilizer extending in a proximal direction. These and other objects are also achieved by a method comprising attaching the apparatus to a wheel hub assembly and attaching the apparatus to the axle. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1 . A disassembled view of an embodiment of the apparatus, showing also a wheel hub assembly and axle with axle flange. 
         FIG. 2 . An assembled view of the embodiment of the apparatus shown in  FIG. 1 . 
         FIG. 3 . A disassembled view of an embodiment of the apparatus comprising a reinforcement member. 
         FIG. 4 . A disassembled view of an embodiment of the apparatus comprising an axle adapter and a wheel hub assembly adapter. 
     
    
    
     DETAILED DESCRIPTION 
     All singular terms should be read to include the plural, and vice-versa, unless stated otherwise. Likewise, all masculine pronouns should be read to include the feminine, and vice versa, unless stated otherwise. 
     A. DEFINITIONS 
     The term “proximal” as used herein refers to a direction, the direction being from the outer portion of the vehicle to the inner portion of the vehicle. 
     The term “distal” as used herein refers to a direction that is the opposite of proximal. 
     The term “including” as used herein is non-exclusive, and should be read to mean “including but not limited to.” 
     B. APPARATUS 
     The apparatus comprises a hub assembly fastening point  10 , an axle fastening point  20 , and a stabilizer  30  extending in a proximal direction. The hub assembly fastening point  10  may be fastened to a hub assembly by any means understood in the art, for example by a bolt, post, or screw. Bolts, posts, and screws have the advantage of being compatible with most standard hub assemblies. Alternatively the hub assembly may be fastened to the hub assembly fastening point  10  by more permanent means, such as soldering, welding, flashing, or the two components may be cast or forged together such that the wheel hub assembly  110  is an integral part of the apparatus. The hub assembly may be fastened to the hub assembly fastening point  10  by gluing, for example with metal glue or epoxy. 
     The axle fastening point  20  may be fastened to the axle by any means understood in the art, including those described above. For example, the axle fastening point  20  may be secured to an axle flange  40 . Fastening to the axle flange  40  can be by any suitable method, for example by bolts that are often integral to the axle flange  40 . The integral bolts have the advantage of being simple to attach and they are engineered to carry the vehicle&#39;s weight. Securing the apparatus to the axle flange  40  has the advantages of easy installation and enhanced structural strength. 
     The stabilizer  30  may serve to position the apparatus parallel to the fractured axle  50  and increase the load-bearing capacity of the apparatus. The stabilizer  30  may, for example, extend into the interior of the fractured axle  50 . In some such embodiments the stabilizer  30  is cylindrical or rod-shaped, and allows the fractured axle  50  to rotate while the apparatus stays in place. In some embodiments the stabilizer  30  also serves to seal the fractured axle  50 , preventing leakage of the axle lubricant from the fractured end. In some embodiments the stabilizer  30  sheaths the axle. In other embodiments the stabilizer  30  may contact the axle in any way known to those skilled in the art that is suitable to orient and support the apparatus. 
     Some embodiments of the apparatus comprise: a hub assembly attachment member  60  comprising the hub assembly fastening point  10  for securing the wheel hub assembly  110  to the apparatus; an axle attachment member  70  positioned proximally to the hub assembly attachment member  60  comprising the axle fastening point  20  for securing the apparatus to the axle; the stabilizer  30  connected to at least one of the hub assembly attachment member  60  and the axle flange  40  attachment member; wherein the hub assembly attachment member  60  and the axle attachment member  70  are secured to one another. 
     In some embodiments of the apparatus, the hub assembly attachment member  60  is a plate perpendicular to the axle. The plate comprises one or more hub assembly attachment points. In some embodiments, there are three hub assembly attachment points. In other embodiments, there may be four, five, six, seven, eight, or more hub assembly attachment points. There may be any number of hub assembly attachment points, corresponding to the number of bolt-holes, post-holes, or threaded holes present on the proximal side of the hub assembly for the particular vehicle. In some embodiments, there are fewer hub assembly attachment points than there are bolt-holes or threaded holes present on the proximal side of the hub assembly of the vehicle. For vehicles in which the hub assembly employs another means of attachment to the axle, the hub assembly attachment point may be any compatible fastener. 
     In some embodiments of the apparatus, the hub assembly attachment member  60  and the axle attachment member  70  are secured to one another by a fastening element  80 . The fastening element  80  may be any appropriate means of fastening known to those skilled in the art, for example a bolt, post, or screw. The fastening element  80  should be sufficiently strong to withstand the load of the vehicle and the shock of normal driving. Optionally the fastening element  80  will be sufficiently strong to withstand the shock of off-road driving or driving at highway speeds. 
     In some embodiments of the apparatus the hub assembly attachment member  60  further comprises a first inter-member fastening point  91  for receiving the fastening element  80  and the axle attachment member  70  further comprises a second inter-member fastening point  92  for receiving the fastening element  80 . The inter-member fastening points serve to connect the hub assembly attachment member  60  to at least one of the axle attachment member  70  and a reinforcement member. There may be any number of first and second inter-member fastening points  92 . Having fewer inter-member fastening points has the advantage of ease of installation. Having more numerous inter-member fastening points has the advantage of strength and redundancy. Certain embodiments of the apparatus comprise 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, and more than 10 first inter-member fastening points  91  and further comprise 2, 3, 4, 5, 6, 7, 8, 9, 10, and more than 10 second inter-member fastening points  92 . 
     In some embodiments of the apparatus, the axle fastening point  20  is configured to secure the apparatus to an axle flange  40 . Such configuration can take the form of hole or guide for a fastener, such as a bolt, post, or screw. The fastening point may be configured to accept the bolts that are integral to the axle flange  40  (in which case the fastening point would be a hole of appropriate diameter). If the fastening point is configured to accept the bolts that are integral to the axle flange  40 , it has the advantage of ease of installation, reversibility of attachment, and durability. The fastening points may also be bolts that are integral to the apparatus, for example if the axle flange  40  comprises holes for accepting bolts. The fastening points may also be bolt-holes, post-holes, or screw-holes for accepting such fasteners that may also be attached to the axle flange  40 . In some embodiments the fastening points will be configured identically to the means used for fastening the brake housing to the axle flange  40  for a particular model (or models) of vehicle. 
     Any number of axle fastening points  20  may be present. If the axle fastening point  20  is configured to secure the apparatus to an axle flange  40 , the number of axle fastening points  20  will often depend on the configuration of the axle flange  40 . Having fewer axle fastening points  20  has the advantage of ease of installation. Having more numerous axle fastening points  20  has the advantage of strength and redundancy. Certain embodiments of the apparatus comprise 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, and more than 10 axle fastening points  20 . 
     In some embodiments of the apparatus, the hub assembly fastening point  10  is configured to secure the wheel hub assembly  110  to the apparatus in a reversible manner. In some embodiments of the apparatus, the axle fastening point  20  is configured to reversibly secure the axle to the apparatus. Such embodiments have the advantages of allowing re-use of the apparatus, not requiring that the apparatus be irreversibly mated to a wheel hub assembly  110  or axle, and ease of removal once the apparatus is no longer needed. Reversible securing can be achieved by any suitable means understood in the art. 
     Some embodiments of the apparatus further comprise an axle flange  40  secured to the axle fastening point  20 . In such embodiments the apparatus is at least partially installed to the vehicle. 
     In some embodiments of the apparatus the stabilizer  30  is connected to the hub assembly attachment member  60  and the axle attachment member  70  further comprises a first opening  101  to receive the stabilizer  30 . When installed, the stabilizer  30  passes through the first opening  101  to contact the axle. In some embodiments the stabilizer  30  is connected to the hub assembly attachment member  60  via welding or flashing. In other embodiments the stabilizer  30  is connected to the hub assembly attachment member  60  by a glue or a fastener. In other embodiments the stabilizer  30  is connected to the hub assembly attachment member  60  during manufacturing (for example, as a single workpiece). 
     Some embodiments further comprise the wheel hub assembly  110  secured to the hub assembly fastening point  10 . The apparatus may be stored with the wheel hub assembly  110  secured to the hub assembly fastening point  10 ; this has the advantage of saving installation time when it becomes necessary to attach the wheel to the vehicle. In some embodiments, the hub assembly attachment member  60  is secured to the hub assembly prior to full installation of the apparatus; in such embodiments, the axle attachment member  70  may be attached to the hub assembly attachment member  60 , or it may remain unattached until installation. 
     Some embodiments of the apparatus further comprise a reinforcement member, wherein the reinforcement member is secured to the hub assembly attachment member  60  and the axle attachment member  70 . In certain of these embodiments, the reinforcement member is positioned proximally to the axle attachment member  70  and the reinforcement member further comprises a second opening  102  to receive at least one of the stabilizer  30  and the axle. The reinforcement member may be positioned proximally to the axle flange  40 , such that the axle flange  40  is clamped between the reinforcement member and the axle attachment member  70 . If the reinforcement member is positioned proximally to the axle flange  40 , the reinforcement member may comprise a second opening  102  to accept at least one of the stabilizer  30  or the axle. The second opening  102  may take the form of a gap between two or more discontinuous sub-members  121  of the reinforcement member. Alternatively, the second opening  102  may be a groove or slot in the reinforcement member or any portion thereof that allows the reinforcement member to be installed around the axle. In one embodiment, the reinforcement member comprises two sub-members  121 , the sub-members  121  being rectangular plates having a semicircular area cut out of a side; then the sub-members  121  are assembled on either side of the axle, and they form a circular cutout that accommodates the axle. This has the advantage of allowing the reinforcement member to be attached proximally to the axle flange  40  without interfering with the rotation of the axle. 
     In some embodiments of the apparatus, the reinforcement member is secured to the hub assembly attachment member  60  and the axle attachment member  70  by a fastening element  80 . The fastening element  80  can be any fastening element  80  described in this disclosure. 
     In some embodiments of the apparatus, the hub assembly attachment member  60  further comprises a first inter-member fastening point  91  for receiving the fastening element  80 , the axle attachment member  70  further comprises a second inter-member fastening point  92  for receiving the fastening element  80 , and the reinforcement member further comprises a third inter-member fastening point  93  for receiving the fastening element  80 . The fastening element  80  can be any fastening element  80  described in this disclosure. 
     In some embodiments of the apparatus, the fastening element  80  is a bolt or a screw. 
     In some embodiments of the apparatus, the hub assembly attachment member  60  further comprises a hub adapter  130  secured to the hub assembly fastening point  10 , the hub adapter  130  comprising a second hub assembly fastening point  170  for securing a hub assembly to the apparatus. The use of a hub adapter  130  has the advantage of allowing the hub assembly attachment member  60  to be attached to plurality of configurations of hub assembly. The hub adapter  130  may take many forms. For example, the hub adapter  130  may comprise a fastening point compatible with the first hub assembly fastening point  10 , and the second hub assembly fastening point  170  may be compatible with one or more models of hub assembly. Either attachment point may be adjustable. One or more hub adapters  130  may be kept with the apparatus, so that the apparatus may be used with more than one type of hub assembly as needed. In such embodiments, the hub adapter  130  may be removably secured to the hub assembly attachment member  60 . 
     Some embodiments of the apparatus further comprise a wheel hub assembly  110  secured to the second hub assembly attachment point. The wheel hub assembly  110  and the second hub assembly point (and thus the hub adapter  130 ) may be stored secured to one another for quick deployment when needed. Alternatively, the wheel hub assembly  110  and the second hub assembly point may be secured to one another at the time of repair. 
     In some embodiments of the apparatus, the hub assembly attachment member  60  comprises a hub assembly socket  140  facing distally. The hub assembly socket  140  may have interior contours  141  that allow the hub assembly to sit snugly within the socket, preventing leakage of lubricant and allowing the hub assembly to be firmly secured to the apparatus. The contours may be beveling, for example. The interior contours  141  may assume any shape. In some embodiments, the interior contours  141  match a given model of hub assembly. The model of hub assembly may be any model. 
     In some embodiments of the method, the axle attachment member  70  further comprises an axle adapter  150  secured to the axle fastening point  20 , the axle adapter  150  comprising a second axle fastening point  180  for securing the apparatus to the axle. The use of an axle adapter  150  has the advantage of allowing the axle attachment member  70  to be attached to plurality of configurations of axles. The axle adapter  150  may take many forms. For example, the axle adapter  150  may comprise a fastening point compatible with the first axle fastening point  20 , and the second axle fastening point  180  may be compatible with one or more models of axle. Either attachment point may be adjustable. One or more axle adapters  150  may be kept with the apparatus, so that the apparatus may be used with more than one type of axle as needed. In such embodiments, the axle adapter  150  may be reversibly secured to the axle attachment members  70 . 
     Some embodiments of the apparatus comprise: a hub assembly attachment member  60  comprising (1) a hub assembly socket  140  facing distally, (2) a hub assembly fastening point  10 , and (3) a stabilizer  30  extending proximally; an axle flange  40  attachment member positioned proximally to the hub assembly attachment member  60 , comprising (a) a first opening  101  to accept the stabilizer  30 , and (b) an axle flange  40  fastening point; a reinforcement member, the reinforcement member comprising a second opening  102  to accept at least one of the stabilizer  30  or the axle; and an inter-member fastener connecting the hub assembly attachment member  60 , the axle flange  40  attachment member, and the reinforcement member. 
     The apparatus may comprise spacers  160  between various parts. Some embodiments of the method further comprise at least one of (1) a first spacer positioned between the hub assembly attachment member  60  and the axle flange  40  attachment member and (2) a second spacer positioned between the axle flange  40  attachment member and the reinforcement member. 
     C. METHODS 
     The disclosure provides methods for securing a wheel to a vehicle. These methods comprise securing an axle fastening point  20  of an apparatus disclosed herein to the axle; and securing the hub assembly fastening point  10  to the hub assembly. In some embodiments, these methods comprise securing any apparatus described herein to an axle flange  40  and securing the apparatus to a wheel hub assembly  110 . 
     Some embodiments of the method further comprise securing the axle attachment member  70  to an axle adapter  150 , said axle adapter  150  comprising an axle attachment member  70  fastening point and a second axle fastening point  180 . Such embodiments may comprise fastening the second axle fastening point  180  to an axle flange  40 . 
     Some embodiments of the method comprise removing a brake assembly from the axle; fastening a hub assembly attachment member  60  to a wheel hub assembly  110 ; fastening an axle flange  40  attachment member to the axle flange  40 ; inserting a stabilizer  30  into the axle, wherein the stabilizer  30  extends in a proximal direction and is connected to at least one of the hub assembly attachment member  60  and the axle flange  40  attachment member; and securing the hub assembly attachment member  60  to the axle flange  40  attachment member. The method may further comprise positioning a reinforcing member proximal to the axle flange  40 ; and securing the reinforcing member to at least one of the hub assembly attachment member  60  and the axle flange  40  attachment member. 
     D. EXAMPLE 
     In one illustrative example, the apparatus is configured to be used with Jeep models manufactured and sold by Dana Corp. These models include the Jeep Cherokee XJ (1990-2000 model years), Jeep Wrangler YJ (1990-1996), Jeep Grand Cherokee ZJ (1993-2006), and Jeep Wrangler TJ (1997-2006). These models were sold with the “C” clip axle. 
     The apparatus of the example comprises an axle flange  40  attachment member, and the axle flange  40  attachment member comprises four axle flange  40  fastening points arranged in a trapezoid. The trapezoid-configured axle flange  40  fastening points correspond to the four posts on the axle flange  40 , allowing easy attachment without additional fasteners. The axle flange  40  attachment member further comprises a first opening  101  to accept the stabilizer  30 . 
     The apparatus of the example further comprises a hub assembly attachment member  60  comprising a hub assembly socket  140  facing distally, a hub assembly fastening point  10 , and a stabilizer  30  extending proximally. The hub assembly socket  140  contains interior beveling allowing a wheel hub assembly  110  from the particular models to form a tight seal in the socket. There are three hub assembly attachment points, corresponding in configuration to the three screw holes on the proximal side of the hub assemblies of the particular models. Thus, bolts or screws can be used to quickly and easy attach the hub assembly to the hub assembly attachment points. 
     The stabilizer  30  is a hollow cylinder that fits inside the axle. The cylinder is sufficiently wide to contact the gasket inside the axle to create a seal against the leakage of axle lubricant. 
     The hub assembly attachment member  60  and the axle flange  40  attachment member are bolted together using four bolts, although the number of bolts is not critical. Each of the bolts passes through a spacer between the two members, so that the two members are held firmly a small distance apart. Each of the four bolts is secured with a nut. 
     Optionally a reinforcement member may be used. The reinforcement member consists of two rectangular plates from which a semicircular area has been removed. Each plate contains two attachment points corresponding to the positions of the four bolts that attach the hub assembly attachment member  60  to the axle flange  40  attachment member. The plates are placed on either side of the axle proximal to the axle flange  40 , and the reinforcement member is then bolted to the axle flange  40  attachment member and the hub assembly attachment member  60 . The bolts pass through four additional spacers  160  between the axle flange  40  attachment member and the reinforcement member. 
     The apparatus of the example is deployed by removing the brake housing from the axle flange  40 , sliding the axle flange  40  attachment member over the posts of the axle flange  40 , screwing or bolting the wheel hub assembly  110  attachment member  60  to the wheel hub assembly  110 , optionally positioning the reinforcement member around the axle, and bolting together the hub assembly attachment member  60 , the axle flange  40  attachment member, and optionally the reinforcement member. 
     E. CONCLUSIONS 
     The foregoing description illustrates and describes the methods, apparatuses and other teachings of the present disclosure. Additionally, the disclosure shows and describes only certain embodiments of the methods, apparatuses and other teachings disclosed, but it is to be understood that the teachings of the present disclosure are capable of use in various other combinations, modifications, and environments and is capable of changes or modifications within the scope of the teachings as expressed herein, commensurate with the skill and/or knowledge of a person having ordinary skill in the relevant art. The embodiments described hereinabove are further intended to explain certain best modes known of practicing the methods, apparatuses and other teachings of the present disclosure and to enable others skilled in the art to utilize the teachings of the present disclosure in such, or other, embodiments and with the various modifications required by the particular applications or uses. Accordingly, the methods, apparatuses and other teachings of the present disclosure are not intended to limit the exact embodiments and examples disclosed herein.