Abstract: Apparatus for molding a composite metal-elastomer styled wheel in which a middle mold part includes a metal wheel disc and rim subassembly. A base mold part seats against the outboard face of the metal wheel in the closed condition of the mold and has a mold cavity surface to provide an ornamental configuration for the outboard face of the decorative plastic body of the composite wheel. A clamp seats against the inboard face of the middle mold part to urge the middle part into sealing engagement with the base mold part. The mold parts are axially separable from one another to open the molding apparatus to clear the middle mold part from said clamp and base mold parts. The clamp includes a funnel adapted for registry with a liquid reaction mixture injection nozzle coupled with injecting mixing apparatus. The funnel has a nozzle passage registering with a bolt-hole pour opening in the disc in the closed condition of the mold.

Abstract: An improved composite metal-elastomer styled automotive-type wheel with a three-dimensionally contoured ornamental outboard face formed by a plastic overlay body permanently adhered or affixed to the outboard face, and an improved molding apparatus and method for constructing such a wheel. A plastic overlay body has an annular row of outboard pockets disposed in radially offset, axially overlapping relation with a annular row of inboard pockets which in turn register with vent openings in the disc to thereby provide air passages through the wheel for brake ventilation. The outboard pockets preferably are disposed radially remote from the center of the wheel close to the wheel rim, and a relatively thin cross-section of plastic material is molded so as to overlie the outboard rim flange to provide a full-face appearance to the wheel.

Abstract: Three-part vertical stack-up mold apparatus for molding a composite styled wheel wherein the middle mold part is metal disc and rim subassembly operable as metal street wheel when a pneumatic tire is mounted on said rim. The lower mold part has a mold cavity surface to define an ornamental configuration for the outboard face of a plastic body of the composite wheel. An upper mold part urges the wheel into sealing engagement with the lower mold part. The lower mold part includes cores adapted for individual registry with disc air vent openings so as to protrude therethrough into the mold cavity in the closed condition of the mold. The upper mold part includes an expansible lid seal juxtaposed in mold cavity sealing relation to the disc inboard face and the cores in the mold-closed condition.

Abstract: A method of molding a cup-shaped article such as integral vehicle wheel rim and disc segment, wherein a plurality of sections of resin-impregnated cloth are placed over a substantially cylindrical mandrel. The cloth sections are substantially identical and have circular central portions which are stacked on the mandrel end face, and oppositely projecting wings which are draped over and are circumferentially staggered around the mandrel sidewall. The central axis of each sheet section is at an angle of 45.degree. to the warp and weft fibers of the section cloth. The sheet sections thus form a mold charge which is compression molded to form an integral vehicle wheel rim and disc segment.

Abstract: A take-apart tire and wheel assembly including a multi-piece wheel rim having axially spaced bead flanges, a rim base, and a pneumatic tubeless tire, preferably adapted to removably receive in its tire inflation chamber a safety runflat insert. The wheel assembly also includes a safety vent for preventing inflation of the tire cavity in the event of improper assembly or disassembly of the safety tire and wheel assembly, including an O-ring seal disposed in a triangular cavity formed between opposing portions of rim segments of the wheel assembly, and mounting studs and associated nuts that releasably clamp the rim segments together with the O-ring captured in compression therebetween. The outboard wheel rim segment includes a wheel mounting disc and may also have a safety inflation valve coupling fixed to the outboard rim segment.

Abstract: A fiber-reinforced composite vehicle wheel that comprises an annular rim for receiving a vehicle tire and a central disc internally spanning the rim for mounting the rim and tire on a vehicle. Mounting openings are formed in the wheel disc in an array that surrounds the wheel axis of rotation, and are received in assembly with a vehicle over mounting studs that project from a mounting plate. Mounting nuts are threaded onto the studs and seated against opposing axially-oriented conical surfaces of the wheel disc surrounding each mounting opening for clamping the wheel firmly against the mounting plate. A layer of antiseize lubricant is located on the disc seating surfaces surrounding the mounting openings prior to assembly of the fastener nuts.

Abstract: A composite styled wheel, and method and apparatus for making the same, including a metal wheel mounting disc and a rim secured thereto adapted to receive a tire thereon, and a composite plastic ornamental overlay covering at least part of the outboard face of the disc and/or rim. The overlay includes a molded in-situ body of relatively high density resilient urethane plastic material permanently affixed to said disc and/or rim and a plastic insert having a weight-to-volume ratio much less than that of the body plastic material. At least the major portion of the insert is disposed radially outwardly from the overlay, aperture wheel mounting and the overlay body plastic material covers the insert so as to completely embed the same in the composite overlay to thereby hide the insert from view and assist in securement thereof to the wheel. The overlay body is cast and cured against the wheel metal with the insert pre-secured thereto.

Abstract: An improved composite metal-elastomer styled automotive-type wheel with a three-dimensionally contoured ornamental outboard face formed by a plastic overlay body permanently adhered or affixed to the outboard face, and an improved molding apparatus and method for constructing such a wheel. A plastic overlay body has an annular row of outboard pockets disposed in radially offset, axially overlapping relation with a annular row of inboard pockets which in turn register with vent openings in the disc to thereby provide air passages through the wheel for brake ventilation. The outboard pockets preferably are disposed radially remote from the center of the wheel close to the wheel rim, and a relatively thin cross-section of plastic material is molded so as to overlie the outboard rim flange to provide a full-face appearance to the wheel.

Abstract: A road wheel for a track laying vehicle comprising a metallic disc and rim part wherein the rim portion of the part is of toroidal geometry. An elastomeric tire tread is bonded to the outer surface of the rim part and has a cylindrical outer face adapted for engagement with the track treads of the track laying vehicle. The cross sectional thickness of the metallic disc and rim part is substantially uniform throughout the same. The rim portion has a radially in-turned flange at the free end thereof extending at an acute angle to the axis of the road wheel. The disc portion merges with the rim portion integrally through a bend portion and extends radially inwardly a given distance to provide a track lug wear surface. The disc portion also has a reverse bend offset axially toward the outer free edge of the rim portion to provide clearance for track guide lugs in the operation of said wheel.

Abstract: A compression mold for manufacture of a fiber-reinforced composite vehicle wheel that has a circumferential array of radially reciprocable rim mold sections, a lower disc mold section affixed to a mold base, and an upper disc mold section axially reciprocable with respect to the lower disc mold section from an upper or retracted position to a lower or closed position in which opposing surfaces of the various mold sections form a wheel mold cavity. The radially reciprocable rim mold sections are slidably mounted on a retainer which is carried by springs above the mold base surrounding the lower disc mold section and are engaged by the upper disc mold section during downward motion of the latter so that the upper disc mold section and the rim mold sections move conjointly with respect to the lower disc mold section toward the closed cavity-defining position of all mold sections.

Abstract: A method and apparatus (50 or 110) for forming bolt and center-pilot mounting openings (36, 30) in vehicle wheels (16 or 112), particularly styled-disc vehicle wheels. A preformed rim and disc assembly is engaged and fixtured around the rim bead seat (20, 22) with the inboard disc face resting on a lower die assembly (82) and without plastic deformation to the rim or disc. An upper die assembly (52) having an array of bolt hole punches (56) is moved into piercing-and-coining engagement with the disc to form the bolt openings. Continued motion of the upper die assembly pushes the disc and lower die assembly into shearing engagement with a center punch (76 or 76a or 76b) which forms the center-pilot opening. The axes BH, CH, BS) of the bolt openings and/or center-pilot opening and/or bead seats may be aligned or offset from each other.

Abstract: Method for punch forming center pilot opening or other wheel mounting surfaces in a pierceable metal performed wheel disc blank mounted internally of the wheel rim. A combination pierce and shave punch forms the disc opening in a single working stroke and produces a one-piece scrap slug containing both the pierced and shaved metal removed from the disc. The punch has a correlated dimensional relationship between disc material thickness, pierce punch diameter, shave punch diameter and shave punch set back from the pierce punch. A smoother, more cylindrical and more dimensionally consistent opening surface is obtained than with conventional pierce-only punches.

Abstract: Method for molding a composite metal-elastomer styled wheel in which a middle mold part consists of a metal wheel disc and rim subassembly. A base mold part seats against the outboard face of the metal wheel in the closed condition of the mold and has a mold cavity surface to provide an ornamental configuration for the outboard face of the plastic body of the composite wheel. There is a clamp which includes a funnel adapted for registry with a liquid reaction mixture injection nozzle coupled with injecting mixing apparatus. The funnel has a nozzle passage registering with a pour opening in the disc in the closed condition of the mold. A sprue pin is affixed to the base mold part in juxtaposed relation to the disc pour opening and cooperates with the margin of the pour opening to define a restricted access opening to the mold cavity during the injection pour of the urethane reaction mixture. The sprue pin is operable to restrict back-flow of the reaction material during gelation of the same in the cure cycle.

Abstract: A method and apparatus for making a composite styled wheel of the type including a metallic disc and rim and an ornamental plastic overlay permanently affixed to the disc. A disc and rim subassembly is placed in a mold. A retainer is formed as a separate part and releasable secured in the mold. A reactive plastic liquid mixture is injected into the mold cavity and the retainer is engulfed in the plastic material and permanently secured to the plastic overlay.

Abstract: A take-apart wheel rim and disc assembly for use in a safety tire and wheel assembly which includes a pneumatic tubeless tire. The wheel includes an inboard rim part, a wheel mounting disc having an outer marginal flange telescoped into and secured to the inboard rim part, the disc flange having an outer surface protruding axially outboard beyond and clear of the inboard rim part. An outboard rim part telescopically received from an axially outboard direction over the disc flange, an O-ring seal disposed between the disc and opposing surfaces of the inboard and outboard rim parts, and a clamp ring for axially clamping the outboard and inboard rim parts together with the O-ring captured in compression between the disc and the opposing surfaces of the rim parts to seal against air leakage. The disc has an air bleed vent structure outboard of the O-ring and normally sealed from the tire cavity by the O-ring.

Abstract: A runflat safety insert and safety tire and wheel assembly which include a take-apart multi-piece wheel rim and safety inserts extending circumferentially around the rim to clamp the tire bead toes against the rim bead flanges. The insert is a sheet metal annulus of generally channel shape in radial cross section open at its radially inner periphery between its side edges. The annular has a central bight portion extending generally axially and bounded by radially in-turned leg portions. The leg portions diverge relative to one another radially inwardly towards the tire bead toes and terminates in toe portions bearing generally flat against the interior surfaces of the tire toe beads. An elastomeric tread is bonded to the outer surface of the central bight portion. The annulus is made up of a pair of semi-circular members having interengageable mating ends releasably interconnected to form a complete annulus.

Abstract: A method and apparatus (50 or 110) for forming bolt and center-pilot mounting openings (36, 30) in vehicle wheels (16 or 112), particularly styled-disc vehicle wheels. A preformed rim and disc assembly is engaged and fixtured around the rim bead seat (20, 22) with the inboard disc face resting on a lower die assembly (82) and without plastic deformation to the rim or disc. An upper die assembly (52) having an array of bolt hole punches (56) is moved into piercing-and-coining engagement with the disc to form the bolt openings. Continued motion of the upper die assembly pushes the disc and lower die assembly into shearing engagement with a center punch (76or 76a or 76b) which forms the center-pilot opening. The axes (BH, CH, BS) of the bolt openings and/or center-pilot opening and/or bead seats may be aligned or offset from each other.

Abstract: Apparatus and method for manufacturing a vehicle wheel rim and disc assembly with controlled lateral runout characteristics, as well as the resulting wheel and a pneumatic tire and wheel assembly having overall improved ride characteristics. The method and apparatus of the invention contemplate fixturing of a preformed rim so that the average plane of the rim bead seats is at preselected orientation with respect to axis of interference press-fit of a preformed disc therein, and thus at preselected orientation with respect to the wheel mounting plane defined by the inboard disc surface. In one implementation of the invention, the average bead seat plane is made nominally parallel to the wheel mounting plane by selective adjustment of the fixturing bead seat locators, so as to minimize lateral runout of the resulting wheel.

Abstract: A composite styled wheel having a metal wheel mounting disc and rim secured together and adapted to receive a tire thereon, and a plastic ornamental overlay body permanently affixed and covering at least a part of the outboard face of the disc and/or rim. The body is made of an elastomeric material, and its outboard face has a decorative contour exposed to view from the outboard side of the wheel. Hub cap retainer grooves or pockets are provided in the outboard face of the body adapted to individually yieldably engage and retain attachment prongs of a hub cap for removable attachment of the same to the wheel. Each of the grooves or pockets has an opening at an outboard face of the body with juxtaposed entrance edges spaced apart a distance less than a maximum transverse dimension of the associated prong to provide an interference fit therewith. Each groove or pocket also has an interior wall surface defining an undercut relationship relative to the opening edges.

Abstract: Apparatus for molding a fiber-reinforced wheel construction having an imperforate disc structure. The wheel comprises a disc portion having reinforcing fibers in substantially random orientation disposed predominantly in planes perpendicular to the wheel axis, and a rim portion having directional first reinforcing fibers substantially parallel to each other and oriented circumferentially of or substantially parallel to the wheel axis, or both, and second reinforcing fibers which are substantially randomly oriented circumferentially of the wheel axis. An apparatus for molding the wheel features radially movable rim mold section and axially reciprocable disc mold sections all having mold surface contours for forming a molded composite wheel of desired configuration.