Vehicle wheel cover retention system and method for producing same

This application claims the benefit of U.S. Provisional Application Ser. No. 60/728,515, filed Oct. 20, 2005.

This invention relates in general to vehicle wheels and, in particular, to an improved vehicle wheel cover retention system and method for producing the same.

Full or partial vehicle wheel covers of the removable type are well known and have been used for many years to enhance the styling of conventional, stamped wheel discs. Also, it is known to permanently secure a full or partial wheel cover to a vehicle wheel using an adhesive.

This invention relates to a vehicle wheel cover retention system for securing a wheel cover to a vehicle wheel. In one embodiment, the vehicle wheel cover retention system comprises a wheel formed from a suitable material and including an outboard face having a retention groove formed therein near an outboard flange thereof; and a wheel cover formed from a suitable material and including an outer portion having a tab formed thereon and an outer annular extension extending radially outwardly relative to the tab toward the outboard flange of the wheel; wherein the tab is received in the retention groove to secure the wheel cover to the wheel.

Other advantages of this invention will become apparent to those skilled in the art from the following detailed description of the preferred embodiments, when read in light of the accompanying drawings.

FIG. 1 is a view of a first embodiment of a vehicle wheel including a wheel cover retention system.

FIG. 2 is a view of a portion of the first embodiment of the vehicle wheel illustrated in FIG. 1 .

FIG. 3 is a sectional view of a portion of the first embodiment of the vehicle wheel illustrated in FIG. 1 .

FIG. 4 is a view of a portion of a second embodiment of a vehicle wheel including a wheel cover retention system.

Referring now to the drawings, there is illustrated in FIG. 1 a portion of a vehicle wheel, indicated generally at 10 , including a first embodiment of a wheel cover retention system, indicated generally at 46 . The vehicle wheel 10 can be of any suitable type of material or materials, such as for example, steel, aluminum and alloys thereof, and can 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 Archibald, 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 euro-flange 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.

As shown in FIG. 1 , in the illustrated embodiment the vehicle wheel 10 is a one piece full cast aluminum wheel and includes a wheel rim, indicated generally at 12 , and a wheel disc, indicated generally at 14 . The vehicle wheel 10 defines a horizontal or longitudinal vehicle wheel axis X. Alternatively, the construction, material and/or make-up of the vehicle wheel 10 may be other than illustrated if so desired.

In the illustrated embodiment, the wheel rim 12 includes an inboard tire bead seat retaining flange 20 , an inboard tire bead seat 22 , a generally axially extending well 24 , an outboard tire bead seat 26 , and an outboard tire bead seat retaining flange 28 . Alternatively, the construction, material and/or make-up of the wheel rim 12 may be other than illustrated if so desired.

In the illustrated embodiment, the wheel disc 14 includes a generally centrally located wheel mounting surface or portion 30 , an outer annular portion 32 , and defines an outer surface or outboard face 34 . The wheel mounting surface 30 of the wheel disc 14 is provided with a centrally located pilot aperture 30 A and a plurality of lug bolt receiving holes 30 B circumferentially spaced around the pilot aperture 30 A (only one of such lug bolt receiving holes 30 B illustrated in FIG. 1 ). The lug bolt receiving holes 30 B receive lug bolts (not shown) and nuts (not shown) for securing the vehicle wheel 10 on an axle (not shown) of a vehicle. Also, the wheel disc 14 also includes one or more vent windows formed therein (not shown). Alternatively, the construction, material and/or make-up of the wheel disc 14 may be other than illustrated if so desired.

As best shown in FIG. 2 , the wheel cover retention system 40 includes a first retention element or feature, indicated generally at 42 , and a second retention element or feature, indicated generally at 44 . As will be discussed below, the first retention element 42 is formed in the outboard face 34 of the wheel disc 14 , and the second retention element 44 is provided on a wheel cover, indicated generally at 50 .

In the illustrated embodiment, the first retention element 42 is preferably formed in the outboard face 34 of the outer annular portion 32 of the wheel disc 14 near or proximate to the outboard tire bead seat retaining flange 28 of the wheel rim 12 . In the illustrated embodiment, the first retention element 42 is formed as a generally radially outwardly circumferentially extending continuous groove which is formed in the outboard face 34 of the outer annular portion 32 of the wheel disc 14 .

As best shown in FIG. 2 , the first retention element 42 includes a circumferentially extending first or outer surface 42 A and a circumferentially extending second or inner surface 42 B. In the illustrated embodiment, the first surface 42 A is preferably spaced a first radial distance R 1 from a generally axially extending outer surface 28 A of the outboard tire bead seat retaining flange 28 of the wheel rim 12 . The second surface 42 B is spaced a second radial distance R 2 from the outer surface 28 A of the outboard tire bead seat retaining flange 28 of the wheel rim 12 .

In the illustrated embodiment, the first radial dimension R 1 is greater than the second radial dimension R 2 to thereby produce the first retention element 42 in the outboard face 34 of the wheel disc 14 . Preferably, the first radial dimension R 1 is in the range from about 1 mm to about 5 mm greater than the second radial dimension R 2 . More preferably, the first radial dimension R 1 is about 2 mm greater than the second radial dimension R 2 . Also, in the illustrated embodiment, the second radial dimension R 2 is preferably is of a sufficient dimension in order to provide a generally radially extending outermost surface 34 A on the outboard face 34 of the wheel disc 14 adjacent the outer surface 28 A of the outboard tire bead seat retaining flange 28 . Alternatively, one or both of the first and second radial distances R 1 and R 2 may be other than illustrated and described if so desired.

In the illustrated embodiment, the first retention element 42 extends a generally first axial distance A 1 from the outermost surface 34 A of the wheel disc 14 to a generally radially extending inner surface 42 C of the first retention element 42 . A second axial distance A 2 is defined between the outermost surface 34 A of the wheel disc 14 and a generally radially extending inner surface 28 B of the outboard tire bead seat retaining flange 28 . Preferably, the first axial distance A 1 is in the range from about one-third to about three-quarters the second axial distance A 2 . Alternatively, the first axial distance A 1 and/or the second axial distance A 2 may be other than illustrated and described if so desired.

In the illustrated embodiment, with the vehicle wheel 10 being a cast aluminum wheel, the first retention element 42 is preferably machined in the outboard face 34 of the outer annular portion 32 of the wheel disc 14 to predetermined tolerances following the casting of the vehicle wheel 10 in order to provide the retention purpose or function to be discussed below. Alternatively, the shape, construction and/or make-up of the first retention element 42 may be other than illustrated if so desired. For example, the first retention element 42 may be a plurality of non-continuous grooves and/or may have a different configuration than that which is illustrated if so desired.

Also, the first retention element 42 may be formed during or subsequent to the manufacture of the wheel disc and/or the vehicle wheel itself by suitable methods if so desired. For example, in the case of a cast aluminum wheel, the retention element may be formed in situ during the casting of the wheel or may be machined subsequent to the casting process. In the case of a fabricated vehicle wheel, the first retention element 42 may be formed either during the manufacture of the wheel disc, such as for example, by spinning or stamping, or may be formed subsequent to the manufacture of the wheel disc, such as for example, by machining. Also, the particular shape, profile and/or location of the first retention element 42 may be other than illustrated if so desired.

In the illustrated embodiment, the wheel cover 50 includes a first or inner portion, indicated generally at 52 , and a second or outer portion, indicated generally at 54 . The wheel cover 50 is shown in this embodiment as preferably being formed from a plastic material and is preferably formed as a one-piece wheel cover. The wheel cover 50 has an inner surface 50 A and an outer surface 50 B. At least the outer surface 50 B may be painted, chrome-plated or otherwise adorned or decorated if so desired. Also, the inner surface 50 A of the wheel cover 50 may generally follow the contour of the adjacent outboard face 34 of the wheel 10 or the inner surface 50 A may have selected portions which are spaced apart from the outboard face 34 to impart styling to the wheel 10 if so desired. Alternatively, the wheel cover 50 can be formed from other materials, such as metal and/or can be a multi-piece wheel cover formed of like or unlike materials if so desired. In addition, the wheel cover 50 may cover substantially the entire outboard face 34 of the vehicle wheel 10 or may cover only desired portions of the outboard face 34 .

In the illustrated embodiment, the second retention element 44 is a tab or protuberance extending from the inner surface 50 A of the cover 50 and provided at least along a portion of the outer portion 54 of the cover 50 . In the illustrated embodiment, the second retention element 44 is preferably a continuous tab and has a shape which may generally be complimentary to the shape of the first retention element 42 . The second retention element 44 is adapted to engage or be received into the first retention element 42 in order to secure or retain the wheel cover 50 on the vehicle wheel 10 . The second retention element 44 includes an outermost circumferential surface 44 A which is spaced a third radial distance R 3 from the outer surface 28 A of the outboard tire bead seat retaining flange 28 . In the illustrated embodiment, the third radial distance R 3 is preferably slightly greater then the second radial distance R 2 and less than the first radial distance R 1 in order to ensure that the tab 44 is received into the first retention element 42 . Alternatively, the third radial distance R 3 and/or the construction or make-up of the second retention element 44 may be other than illustrated and described if so desired. For example, the second retention element 44 may be a plurality of individual tabs spaced circumferentially about the cover 50 which are adapted to be received into the first retention element 42 shown in this embodiment or into a plurality of individual grooves if so desired.

As best shown in FIG. 2 , in this embodiment the wheel cover 50 includes an outer annular portion or extension 56 . The portion 56 includes an outermost surface 56 A which extends radially outwardly relative to the outermost surface 44 A of the second retention element 44 and toward the outer surface 28 A of the outboard tire bead seat retaining flange 28 . The outermost surface 44 A of the portion 56 is preferably spaced a fourth radial distance R 4 from the outer surface 28 A of the outboard tire bead seat retaining flange 28 so as not to engage or contact the outer surface 28 A. Alternatively, the fourth radial distance R 4 and/or the construction or make-up of the portion 56 may be other than illustrated and described if so desired. Also, the particular shape, profile and/or location of the second retention element 44 may be other than illustrated if so desired.

In the illustrated embodiment, an adhesive, indicated generally at 60 only in FIG. 1 , is preferably used to secure the wheel cover 50 to the vehicle wheel 10 . Suitable adhesives 60 may include but are not limited to the use of one or a combination of more than one of adhesives selected from the group consisting of silicone, two-part epoxy, urethane, double-sided tape, expanding foam, and the like. The adhesive 60 may be selectively applied in a pre-assembly pattern so as to result in a full surface post-assembly pattern (not shown), or in a non-full surface post-assembly pattern (as shown in FIG. 1 ), i.e., a post-assembly pattern which has voids or gaps therein. Also, in addition to the adhesive 60 , other mechanical means, such as for example, snap tabs and fasteners or other suitable mechanical members (not shown), may be used to assist in securing the wheel cover 50 the vehicle wheel 10 if so desired.

Turning now to FIG. 3 and using like reference numbers to indicate corresponding parts, there is illustrated a second embodiment of a portion of a vehicle wheel, indicated generally at 70 , including a second embodiment of a wheel cover retention system, indicated generally at 72 . In this embodiment, a wheel cover 74 includes a second tab 76 provided thereon which is located radially outwardly relative to the tab 44 . The tab 74 is preferably a continuous tab and is operative to space apart at least a portion of an inner surface 78 A of an outer annular portion or extension 78 of the wheel cover 72 from engagement with the adjacent outboard face 34 of the wheel 10 . Preferably, to accomplish this, the axial length of the tab 44 in this embodiment is slightly longer than that of the tab shown in the embodiment of FIGS. 1 and 2 . Also, adhesive 60 may be selectively deposited between the inner surface 78 A and the outboard face 34 of the disc 14 if so desired. Alternatively, the construction, location or make-up of the second tab 76 may be other than illustrated if so desired.

Turning now to FIG. 4 and using like reference numbers to indicate similar parts, there is illustrated a third embodiment of a portion of a vehicle wheel, indicated generally at 80 , including a second embodiment of a wheel cover retention system, indicated generally at 82 . In this embodiment, a wheel cover 84 includes a second tab 86 provided thereon which is located radially outwardly relative to the tab 44 . The tab 84 is preferably a continuous tab and extends inwardly from an inner surface 88 A of an outer annular portion or extension 88 of the wheel cover 82 . Also, in this embodiment, the wheel 80 includes a second groove or recess 90 formed therein which is located radially outwardly relative to the groove 42 . The groove 90 is preferably a continuous groove and is operative to receive the second tab 86 of the wheel cover 80 . In the illustrated embodiment, the groove 90 is larger than the tab 86 so as to loosely receive the tab 86 therein. However, the groove 90 may be sized and shaped generally complimentary to the tab 86 so that the tab 86 is received therein in an interference or press-fit if so desired. Also, as shown in the embodiment, the inner surface 88 A of the outer annular portion 88 preferably contacts at least a portion of the outboard face 34 of the disc 14 . Alternatively, the construction, location or make-up of the second tab 86 and/or the second groove 90 may be other than illustrated if so desired.

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 various 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.