Land vehicles: wheels and axles – Wheel – Compression wheel
Reexamination Certificate
2000-06-30
2001-11-13
Morano, S. Joseph (Department: 3617)
Land vehicles: wheels and axles
Wheel
Compression wheel
C301S063107, C301S091000
Reexamination Certificate
active
06315367
ABSTRACT:
BACKGROUND OF THE INVENTION
This invention relates in general to a vehicle wheels and in particular to a light weight cast wheel for commercial highway vehicles and an apparatus for casting such a wheel.
Light weight commercial vehicle wheels formed from an aluminum alloy are becoming increasingly popular. It is known to fabricate such wheels from two pieces. A full face wheel disc is formed by a conventional process, such as casting or forging, from an alloy of a light weight metal, such as aluminum, magnesium or titanium. The wheel disc includes a centrally located wheel mounting flange and an outer annular flange which forms an outboard tire bead seat retaining flange. The centrally located wheel mounting flange has a centrally located pilot hole and a plurality of lug bolt holes spaced circumferentially around the pilot hole. The lug bolt holes receive lug bolts which carry nuts for securing the wheel on an axle of a vehicle. The outer annular flange of the disc is preferably provided with a plurality of wheel openings or windows spaced circumferentially around the pilot hole. The perimeter of the outer flange is formed into an outboard tire bead seat. An outboard tire bead retaining flange extends in an outward radial direction from the outboard end of the tire bead seat.
The wheel disc is attached to the outboard end of a partial wheel rim at the outboard tire bead seat with a continuous air-tight circumferential weld. The partial wheel rim is formed by a conventional process, such as rolling and includes a wheel well which extends in an axial inboard direction from the outboard tire bead seat. The well terminates in an inboard tire bead seat. An inboard tire bead retaining flange extends radially from the inboard end of the inboard tire bead seat. The wheel rim is usually formed from the same alloy as the wheel disc; however, the rim can be formed from a different metal. To reduce cost, the wheel rim can be rolled from steel.
Alternately, a one piece wheel can be formed by a conventional process, such as casting or forging. A one piece wheel eliminates the circumferential weld between the wheel disc and wheel rim and the potential for air leaks therethrough. However, because of the geometry of the molds or dies used, such wheels tend to have thick cross sections at the juncture of the wheel disc outer annular flange and the outboard end of the wheel rim.
SUMMARY OF THE INVENTION
This invention relates to a light weight cast wheel for a commercial highway vehicle and an apparatus for casting such a wheel.
The additional metal contained in the thick cross section of the juncture of the wheel disc outer annular flange and the outboard end of the wheel rim of a one piece wheel increases the weight of the wheel, which is added to the unsprung weight of the vehicle suspension. Accordingly, it would be desirable to include a lightener recess or plurality of lightener pockets in this portion of the vehicle wheel. Such a recess could be cut into the wheel by machining the interior of the wheel. Alternately, such recesses could be formed with movable cores which would be included in the wheel mold used to cast wheel. However, such methods are time consuming and costly. Accordingly, it would be desirable to provide a inexpensive method for forming a lightener recess in a one piece vehicle wheel.
The present invention contemplates a one piece commercial highway vehicle wheel which includes an annular rim having an outboard tire bead seat formed thereon. The wheel also includes a circular wheel disc extending across the outboard end of the wheel rim. A lightener recess is formed in the wheel rim which extends radially into the outboard end of the rim beneath the outboard tire bead seat.
In the preferred embodiment, the recess is a continuous circumferential recess. Also, the wheel is formed from an alloy of one of the group of aluminum, titanium and magnesium.
The invention also contemplates an apparatus for casting a one piece commercial highway vehicle wheel which includes a multiple-piece wheel mold having a mold base member which supports a plurality of movable side members and a movable top core. The top core cooperates with the base side members to define a mold cavity. The apparatus further includes a core insert which is carried by the top core and extends radially into the mold cavity to form a lightener recess in a wheel casting cast in the mold cavity.
It is contemplated that the core insert is annular and formed from a porous material. Additionally, the top core includes at least one vent aperture formed therethrough, the vent aperture being adjacent to the core insert. It is further contemplated that the apparatus includes a device which generates a vacuum. The vacuum generating device is connected to the vent apertures and applies a vacuum to the core insert to remove gases from the mold cavity. Furthermore, the core insert can be hollow.
The base member also can have a central sprue opening formed therethrough and be adapted for mounting upon a low pressure casting machine with the mold cavity communicating with the low pressure casting machine through the sprue opening.
The present invention also contemplates a process for casting a one piece commercial vehicle wheel which includes providing a multi-piece wheel mold having a base member supporting a plurality of movable side members and a movable top core. The mold components cooperate to define a mold cavity. A core insert is mounted within the cavity defined by the wheel mold. The wheel mold is closed and the mold cavity is charged with molten metal. The molten metal is allowed to solidify. The wheel mold is then opened and the wheel casting and core insert removed. The core insert is removed from the wheel casting and the casting finished to form a vehicle wheel. The process also can include providing a vacuum generating device which is connected thorough passageways formed in the top core to the core insert. The vacuum generating device being actuated while the molten metal solidifies to remove gases from the mold cavity.
Various objects and advantages of this invention will become apparent to those skilled in the art from the following detailed description of the preferred embodiment, when read in light of the accompanying drawings.
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Lawrence Garth
Mason Douglas P.
McGrath Michael
Nitz John D.
Prieto Romulo A.
Hayes Lemmerz International Inc.
MacMillan Sobanski & Todd LLC
Morano S. Joseph
Nguyen Long Bao
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