Vehicle wheel having a connection between a wheel rim and a wheel disc and method for the production thereof

Abstract

Disclosed is a vehicle wheel having a wheel rim and a wheel disc connected to an inner side of the wheel rim. The wheel disc is connected to the wheel rim by a connecting element which is guided through a through-hole of the rim base and inserted in the wheel disc. The through-hole is arranged in the tire seat of the rim base and the connecting element is joined substantially in the direction of the radial extension of the wheel disc which is associated to the tire seat on the inner side of the rim. In the method for producing the wheel the connection between wheel rim and wheel disc is produced in the region of the tire seat of the rim base, and, after the insertion of the connecting element into the wheel disc, a portion of the connecting element protruding the contour of the outer side of the rim of the tire seat is shaped so that the connecting element conforms to the contour of the outer side of the rim of the tire seat.

Claims

1. A method for the production of a vehicle wheel, the wheel including a wheel rim and a wheel disc configured to be connected to an inner side of the wheel rim, comprising: guiding a connecting element through a through-hole formed in a tire seat area of the wheel rim into a corresponding opening formed in the wheel disc, connecting the wheel disc to the wheel rim with the connecting element, and finishing, after said connecting, a portion of the connecting element that projects beyond a contour of the tire seat on an outer side of the rim such that a contour of the connecting element is adapted to match the contour of the tire seat on the outer side of the rim.

2. The method of claim 1 comprising a connection arrangement that includes the connecting element.

3. The method of claim 2 wherein after the joining of the connection arrangement in the wheel rim or wheel disc, a portion of the connection arrangement projecting beyond the contour of the tire seat on the outer side of the rim is finished so that the connection arrangement matches the contour of the tire seat.

4. The method of claim 2 comprising machining the connecting element or the connection arrangement to match the contour of the tire seat on the outer side of the rim.

5. The method of claim 4 wherein the machining comprises at least one of turning, sanding or milling.

6. The method of claim 1 wherein a portion of a head of the connecting element or a radially extended portion of a connection arrangement which comprises the connecting element is embedded in a recess, which corresponds in a form-fit manner, of the through-hole.

Description

BRIEF DESCRIPTION OF THE INVENTION

(1) The vehicle wheel according to the invention and the method according to the invention for the production thereof are described in more detail in the following embodiments. The associated drawings show, in a schematic representation, the following

(2) FIG. 1 an extract of a cross-sectional view of a vehicle wheel according to the invention with a wheel rim and a wheel spider which are connected by means of a countersunk bolt,

(3) FIG. 1a an enlarged detailed view X from the cross-sectional view in accordance with FIG. 1,

(4) FIG. 2 an extract of a cross-sectional view of the vehicle wheel in accordance with FIG. 1 with a countersunk bolt covered using a sealant,

(5) FIG. 3 an extract of a cross-sectional view of a vehicle wheel according to the invention with a wheel rim and a wheel spider which are connected by means of a connection arrangement consisting of a countersunk bolt and a two-part bushing,

(6) FIG. 4 an extract of a cross-sectional view of a first process step, according to the invention, of the production of the connection of a vehicle wheel with a wheel rim and a wheel spider by means of a countersunk bolt,

(7) FIG. 5 an extract of a cross-sectional view of a second process step, according to the invention, of the production of the connection of the vehicle wheel in accordance with FIG. 4,

(8) FIG. 6 an extract of a cross-sectional view of a first process step, according to the invention, of the production of the connection of a vehicle wheel with a wheel rim and a wheel spider using a connection arrangement consisting of a countersunk bolt and a two-part bushing,

(9) FIG. 7 an extract of a cross-sectional view of a second process step, according to the invention, of the production of the connection of the vehicle wheel in accordance with FIG. 6.

DETAILED DESCRIPTION OF THE DRAWINGS

(10) The first embodiment of the invention shows, in FIG. 1, a sectional view of a vehicle wheel according to the invention with a wheel rim 1 and a wheel spider 2 made from aluminium which are connected by means of several countersunk bolts 3 made from stainless steel arranged distributed around the circumference of the wheel rim 1. The sectional view shows the section through the vehicle wheel along the longitudinal axis of one of the connecting elements 3 guided through the rim base of the wheel rim 1 and joined in the wheel spider 2.

(11) The attachment of the wheel spider 2 to the wheel rim 1 occurs in the area of a tire seat 1.1, which is formed in the rim base of the wheel rim 1 between the rim shoulder 1.2 (hump) and the rim flange 1.3 to accommodate a tire 4.

(12) The radial outer contour of the essentially radially extended wheel spider 2 is adapted to the contour of the wheel rim 1 on the inner side of the rim beyond the tire seat 1.1, so that the wheel spider 2 is supported, in the installed state, against the wheel rim 1 in the area of the tire seat 1.1.

(13) Accordingly the through-holes 5, provided for guiding the countersunk bolts 3, are constructed in the tire seat 1.1 of the rim base and essentially radially aligned. On the outer side of the rim each through-hole 5 has a recess, widened in a tapered manner (screwhole), for accommodating the countersunk head 3.1 of the bolt 3.

(14) Each through-hole 5 through the tire seat 1.1 corresponds to one longitudinally extended blind hole 6 which extends, with an essentially radial alignment, deep into the longitudinally extended spoke end of the wheel spider 2. The blind hole 6 has, in an upper portion, a receiving channel 6.1 and, in a deeper, lower portion, a joining channel 6.2 with an internal thread. The countersunk bolt 3 is guided with its elongated smooth shaft portion through the through-hole 4 and through the receiving channel 6.1 of the blind hole 6 and engages, with the external thread of its shaft end, with the internal thread of the joining channel 6.2 of the blind hole 6. The interlocking thread length provides the effective length for the force transmission through the countersunk bolt 3. The elongated, thread-free shaft portion of the countersunk bolt 3 serves to provide a high length of elongation during the absorption of force by the bolt 3. In order, with the countersunk bolt 3, to be able to introduce the maximum possible force into the wheel spider 2 made from aluminium, the thread length of the shaft end engaging with the joining channel 6.2 of the blind hole 6 is at least 2.5 times the screw diameter. The thread-free, upper shaft section of the countersunk bolt 3 is, in this embodiment, approx. twice as large as the thread length of the shaft end.

(15) The longitudinally extended space available in the spoke end of the wheel spider 2 makes it possible to use particularly long connecting elements 3 in the relevant advantageous ratios of effective length and length of elongation.

(16) The countersunk bolt 3 has, for the purpose of screwing it into the wheel spider 2, a hexagonal socket in the countersunk head 3.1. As is more precisely visible from the enlarged detailed view X in FIG. 1a, the countersunk head 3.1 of the bolt 3 is, in the screwed state, arranged countersunk in the screwhole of the rim base in such a way that the flat countersunk head 3.1 at no point protrudes beyond the circumferentially curved rim outer side of the tire seat 1.1.

(17) This is already ensured by the fact that the edge of the flat countersunk head 3.1 orientated perpendicular to the picture plane and in a tangential direction of the cylindrical circumferential surface of the rim base is flush with the adjacent circumferential surface of the tire seat 1.1. Geometrically the result of this is that the surface of the flat countersunk head 3.1 is lower paraxially than the contour of the tire seat 1.1 on the outer side of the rim, as is visible in FIG. 1a.

(18) The countersunk head 3.1 can however, in the screwed state of the bolt 3, also be arranged countersunk in the screwhole of the rim base in such a way that the flat countersunk head 3.1 forms a complete recess in relation to the curved rim outer side of the tire seat 1.1.

(19) In both cases, a projecting contour of the countersunk head 3.1 beyond the rim outer side of the tire seat 1.1 is prevented, so that no burrs or edges protrude into the installation space of the fitted tire and thus the tire 4 is not impeded or damaged in its placing in the tire seat.

(20) The design in accordance with FIG. 2 shows the vehicle wheel in accordance with FIG. 1 in which the countersunk head 3.1 of the countersunk bolt 3 arranged countersunk in the screwhole of the rim base is covered with an elastic sealing compound 7 as a sealant.

(21) For the purposes of better illustration, the tire 4 is not shown here. The covering with the sealing compound 7 takes place in the embodiment in such a way that the remaining cavity of the screwhole above the countersunk head 3.1 is completely filled, whereby the outer surface of the filling is equipped, by means of the sealing compound 7, with a curved contour, which partially corresponds to the outer cylindrical contour of the tire seat 1.1 and thereby completes the contour of the tire seat on the outer side of the rim in a continuous manner.

(22) Hence the existing connections in the tire seat 1.1 continue, even during the operation of the vehicle wheel, to have no disadvantageous influenceeither on the sealing of the tire 4 vis--vis the wheel rim 1 or on the force transmission between tire 4 and wheel rim 1.

(23) The embodiment of the invention in accordance with FIG. 3 relates to a vehicle wheel according to the invention similar to the vehicle wheel in accordance with FIG. 1, whereby a wheel rim 1, whose rim base consists of fibre composite, is connected to a wheel spider 2 made from aluminium.

(24) In the following only the differences vis--vis the embodiment in accordance with FIG. 1 shall be described. The same functional components have the same reference symbols.

(25) In order to attach the wheel spider 2 to the wheel rim 1 made from fibre composite, a combined connection arrangement 8 is provided which has a two-part bushing 9.1, 9.2 made from stainless steel in which the countersunk bolt 3 as a connecting element is guided.

(26) The first bushing part 9.1 arranged in the through-hole 5 has, on the outer side of the rim, an edge area widened in a tapered manner which corresponds to the recess widened in a tapered manner (screwhole) of the through-hole 5 and furthermore is designed to correspond to the countersunk head 3.1. It protrudes on the inner side of the rim beyond the cross section of the rim base.

(27) The second bushing part 9.2 comprises the first bushing part 9.1 protruding on the inner side of the rim and contacts with the rim inner side of the wheel rim 1.

(28) The bushing parts 9.1, 9.2 hence create a favourable separation of the countersunk bolt 3 and of the wheel spider 2 from the rim base of the wheel rim 1, which protects the fibre composite of the rim base from, among other things, unwanted vibratory-rubbing wear.

(29) The countersunk bolt 3 is guided through the first and second bushing parts 9.1, 9.2 into the radially extended blind hole 6 and engages, with the external thread of its shaft end, with the internal thread of the joining channel 6.2 of the blind hole 6.

(30) In the screwed state the radial outer contour of the wheel spider 2 is pressed firmly onto the facing contact surfaces of the first and second bushing parts 9.1, 9.2, whilst the countersunk head 3.1 contacts with the edge area, widened in a tapered manner, of the first bushing part 9.1.

(31) In the same manner as the design in accordance with FIG. 1, in the screwed state the edge area of the first bushing part 9.1 of the connection arrangement 8 is also arranged countersunk in the screwhole of the rim base in the same way as the countersunk head 3.1 of the bolt 3, so that this edge area, at least in a tangential direction of the cylindrical circumferential surface of the rim base, is flush with the rim outer side of the tire seat 1.1.

(32) The result of this, purely geometrically, is that both the flat surface of the countersunk head 3.1 of the bolt 3 and the flat edge area of the first bushing part 9.1 lie, in the sectional plane shown, lower than the cylindrical contour of the tire seat 1.1 on the outer side of the rim, as visible in FIG. 3.

(33) Alternatively, in the screwed state, the countersunk head 3.1 of the bolt 3 and the edge area of the first bushing part 9.1 can also be arranged countersunk in the screwhole of the rim base in such a way that, in addition to the countersunk head 3.1 the entire circumferential edge area of the first bushing part 9.1 also completely forms a recess in relation to the rim outer side of the tire seating 1.1.

(34) By this means, in each case a projecting contour of the countersunk head 3.1 and of the edge area of the first bushing part 9.1 beyond the rim outer side of the tire seat 1.1 is prevented, so that no burrs or edges protrude into the installation space of the tire 4 (not shown here) and thus the tire 4 is not impeded or damaged in its placing in the tire seat 1.1.

(35) With this design it is possible, in the same manner as the design in accordance with FIG. 2, for the connection arrangement 8 arranged countersunk in the screwhole of the rim base to be covered with a sealant 7, and namely preferably in such a way that the screwhole, above the countersunk head 3.1 of the bolt 3 and the edge area of the first bushing part 9.1 on the outer side of the rim, is completely filled with the sealant 7 and the outer surface of the sealant 7 partially completes the outer cylindrical contour of the tire seat 1.1 (not shown).

(36) FIGS. 4 and 5 describe a method according to the invention for the production of a vehicle wheel, similar to the vehicle wheel in accordance with FIG. 1, with a connection of a wheel rim 1 and a wheel spider 2 made from aluminium in the area of the tire seat 1.1 of the wheel rim 1.

(37) The same functional components are given identical reference symbols.

(38) FIG. 4 shows, in a snapshot, a first process step according to the invention of the production of this connection.

(39) By way of connecting elements, bolts 3 made from stainless steel with a large-sized, combined flat-countersunk head 3.2 are used which each have, in addition to a lower, tapered countersunk head portion 3.2.1, an upper, cylindrically shaped flat-head portion 3.2.2, whereby in the latter portion 3.2.2 a hexagonal socket is formed as an installation aid. The cross-sectional views in FIGS. 4 and 5 show one of the bolts 3 representatively for the total number of bolts 3 joined in the area of the tire seat 1.1 around the circumference of the wheel rim 1.

(40) In the process step in accordance with FIG. 4, the bolt 3 is already pushed through the through-hole 5 constructed in the tire seat 1.1 and screwed into a corresponding, essentially radially aligned, longitudinally extended blind hole 6 of the wheel spider 2, whereby the bolt 3 is tightened using a tool (not shown) which engages with the hexagonal socket of the combined flat-countersunk head 3.2.

(41) When all bolts 3 are screwed in, the radial outer contour of the wheel spider 2 is firmly attached to the contour of the wheel rim 1 on the inner side of the rim.

(42) The through-hole 5 through the rim base has, on the outer side of the rim, a recess widened in a tapered manner (screwhole) that corresponds to the shape of the lower countersunk head portion 3.2.1 in which the flat-countersunk head 3.2 of the bolt 3 is embedded while screwing until the tapered countersunk head portion 3.2.1 contacts flat with the recess widened in a tapered manner. A large part of the flat-head portion 3.2.2 remains, in the screwed state of the bolt 3, above the contour of the tire seat 1.1 on the outer side of the rim and forms a projecting portion of the combined flat-countersunk head 3.2.

(43) FIG. 5 shows, in a snapshot, a second process step of the production of the connection of the vehicle wheel in accordance with FIG. 4. In this subsequent process step the projecting portion of the combined flat-countersunk head 3.2 was removed through machining with for example a milling tool. The projecting portion is finished in such a way that the remaining portion of the flat-countersunk head 3.2 embedded in the recess of the through-hole 5, which essentially consists of the countersunk head portion 3.2.1, is adapted to the contour of the tire seat 1.1 on the outer side of the rim so as to faithfully match the contour.

(44) With the finishing of the flat-countersunk head 3.2, the hexagonal socket of the flat-countersunk head 3.2 is, simultaneously and without further assistance, also removed, since its recessing geometry is suitably placed in the flat-head portion 3.2.2 projecting beyond the contour of the tire seat on the outer side of the rim.

(45) Through this finishing of the flat-countersunk head 3.2, a completely continuous pattern of the tire seat 1.1 from the rim shoulder 1.2 to the rim flange 1.3 and circumferentially around the cylindrical circumferential surface of the wheel rim 1 is generated into which the finished flat-countersunk bolt 3 is integrated without any contour discontinuities. Thereby a fit of the tire 4 (not shown here) on the wheel rim 1 that is optimally contacting, tight vis--vis the tire chamber and undisturbed by the connections arranged in the tire seat 1.1, is achieved.

(46) In a third process step (not shown) the finished surface of the flat-countersunk head 3.2 and the contour of the tire seat 1.1 on the outer side of the rim can be covered all over with a thin coating layer to seal the rim base and the through-holes 5.

(47) FIGS. 6 and 7 describe a second method according to the invention for the production of a vehicle wheel, similar to the vehicle wheel in accordance with FIG. 3, with a connection of a wheel rim 1 made from fibre composite and a wheel spider 2 made from aluminium in the area of the tire seat 1.1 of the wheel rim 1.

(48) The same functional components are given similar reference symbols.

(49) FIG. 6 shows a snapshot of a first process step according to the invention for the production of this connection.

(50) The wheel rim 1 and the wheel spider 2 are, unlike in the method in accordance with FIGS. 4 and 5, connected by means of several connection arrangements 8 arranged in the tire seat 1.1 and around the circumference of the wheel rim 1, each of which consist of a flat-countersunk bolt 3 as per the design in accordance with FIG. 4 and a two-part bushing 9.1, 9.2 made from stainless steel. The large-sized first bushing part 9.1 arranged in the through-hole of the tire seat 1.1 has, on the outer side of the rim, in addition to an area widened in a tapered manner, a cylindrically widened edge area which, in the installed state, completely accommodate the tapered countersunk head portion 3.2.1 or the cylindrically shaped flat-head portion 3.2.2 of the flat-countersunk head 3.2.

(51) In order to embed the first bushing part 9.1, widened in a stepped manner, in the through-hole this has, on the outer side of the rim, a recess that is tapered in a stepped manner and cylindrically widened to correspond to the outer shape of the first bushing part 9.1, which (recess), owing to the circumference of the bushing part, reaches up to the rim shoulder 1.2 and the foot of the rim flange 1.3.

(52) Owing to the considerably large external cross section of the cylindrical portion of the bushing part 9.1, a large contact surface of the bushing part is provided, whereby the contact pressure acting on the fibre composite of the rim base is favourably reduced as a result of the longitudinal screw force of the bolt 3.

(53) A second bushing part 9.2 surrounds the first bushing part 9.1 on the inner side of the rim. The bushing parts 9.1, 9.2 completely line the through-hole to protect the rim base made from fibre composite.

(54) In the process step in accordance with FIG. 6, the bolt 3 is already pushed through the first and second bushing parts 9.1, 9.2 in the through-hole and screwed into the corresponding, longitudinally extended blind hole 6 of the wheel spider 2, whereby the bolt 3 is tightened by means of a tool (not shown) which engages with the hexagonal socket of the combined flat-countersunk head 3.2.

(55) When all bolts 3 are screwed, the radial outer contour of the wheel spider 2 is pressed firmly onto the facing contact surfaces of the bushing parts 9.1, 9.2 and in each case the flat-countersunk head 3.2 embedded into the edge area of the first bushing part 9.1 that is widened in a tapered manner and cylindrically widened.

(56) Essentially the flat-head portion 3.2.2 of the bolt 3 and a large part of the cylindrically widened edge area of the first bushing part 9.1 remain, in the screwed state of the bolt, above the contour of the tire seat 1.1 on the outer side of the rim and form a projecting portion of the connection arrangement 8.

(57) FIG. 7 shows in a snapshot the second, subsequent process step of the production of the connection of the vehicle wheel in accordance with FIG. 6, in which the projecting portion of the connection arrangement 8, or the flat-head portion 3.2.2 with the cylindrically widened edge area of the first bushing part 9.1, was removed with a machining tool and finished in a shaping manner in such a way that the remaining portion of the connection arrangement 8 embedded in the recess of the through-hole, essentially consisting of the countersunk head portion 3.2.1 and the edge area, widened in a tapered manner, of the first bushing part 9.1, is adapted to the contour of the tire seat 1.1 on the outer side of the rim so as to faithfully match the contour. Only a small remnant of the cylindrically widened edge area of the first bushing part 9.1 remains when machining occurs and on the one hand offers a generous contact surface for compensation of the surface pressure and on the other hand faithfully matches the contour and thereby, largely irrespective of the space available, is adapted to the contour of the tire seat 1.1 on the outer side of the rim and to the adjacent contour, on the outer side of the rim, of the rim shoulder 1.2 and the rim flange 1.3.

(58) Since the hexagonal socket of the flat-countersunk head 3.2 is arranged in the projecting portion outside of the contour of the tire seat 1.1, this is also removed during the finishing of the flat-countersunk head 3.2.

(59) As a result a completely continuous pattern of the tire seat 1.1, from the rim shoulder 1.2 to the rim flange 1.3 and circumferentially around the cylindrical circumferential surface of the tire seat, is created in which the adjacent connection arrangement 8 on the outer side of the rim made from flat-countersunk bolt 3 and two-part bushing 9.1, 9.2 is integrated without any contour discontinuities.

(60) Thereby a fit of the tire (not shown here) on the wheel rim 1 that is optimally contacting and tight vis--vis the tire chamber, undisturbed by the multi-part connection arrangements arranged in the tire seat 1.1, is achieved.

(61) In a third process step (not shown) it is possible, for the purpose of sealing the rim base and the through-holes, for the finished surface of the connection arrangement 8, or the surface of the remaining flat-head portion 3.2.2 of the flat-countersunk head 3.2 and of the cylindrically widened edge area of the first bushing part 9.1, and also the contour of the tire seat 1.1 on the outer side of the rim, to be covered all over with a thin coating layer.