Wheel assembly including sidewall cover assembly and related methods

Abstract

The present invention relates to a wheel assembly (730) to be coupled to a wheel hub of a vehicle, the wheel assembly may include an inner rim (731) to be coupled to the wheel hub of the vehicle, an outer rim (733) surrounding the inner rim (731), and a gas spring (750) operably coupled between the inner rim (731) and the outer rim (733) to provide a gas suspension allowing relative movement between the inner rim (731) and the outer rim (733). The wheel assembly (730) includes a sidewall cover assembly (701a, 701b), the sidewall cover assembly includes an inner sidewall cover (793), the inner sidewall cover is coupled to the inner rim (731) and extends radially outward toward the outer rim (733). The side wall cover assembly also includes an outer side wall cover (794), which is connected to the outer rim (733) and extends radially inward toward the inner rim (731), and the outer side wall cover is in a sliding overlapping relationship with the inner side wall cover (793), thereby allowing relative movement between the inner side wall cover (793) and the outer side wall cover (794).

Description

Technical Field

[0001] The present invention relates to the field of wheels and, more particularly, to wheel assemblies for vehicles and related methods. Background Art

[0002] A typical wheel may include a rim and a tire surrounding the rim. The tire transfers the load of the vehicle from the axle through the wheel to the ground. Tires (e.g., those found on most vehicles) are pneumatic tires. In other words, a typical tire is pneumatically inflated, such as with air or other gases (e.g., nitrogen). More specifically, air is injected into the space between the rim and the interior of the tire to inflate the tire.

[0003] During operation, because the tire is pneumatically inflated, the tire absorbs forces as the vehicle travels over the road. The tire and associated inflation pressure can be selected to absorb the above-mentioned forces while reducing any deformation. However, in many instances, excessive forces applied to the tire can cause deformation, punctures or blowouts of the tire and / or rim. Typical forces also cause the tread of the tire to wear, and excessive forces can also cause rapid tread wear, which can shorten the life of the tire and reduce the structural integrity of the wheel.

[0004] In order to address the shortcomings of pneumatic-based wheels, non-pneumatic wheels have been developed. By non-pneumatic, it is meant that air or other gas is not injected to inflate the internal volume of the tire. One solution for non-pneumatic wheels is to use a mechanical spring. For example, U.S. Patent No. 911,975 to Gustafson discloses a spring wheel. The secondary spokes are arranged in pairs between the pairs of primary spokes, and thus the members of each secondary spoke pass through opposite sides of a corresponding pair of intersecting stays. Each secondary spoke includes a pair of telescopic members that are pivotally connected at their outer ends to ears formed on the hub and extend into corresponding members at their opposite ends.

[0005] U.S. Patent No. 1,601,518 to Weston discloses a resilient wheel including radial arms. The connection between the hub and the rim member may be provided by pivot pins in the outer ends of these arms on which a journaled connecting rod is provided. The connecting rod is pivotally articulated with a curved lever which in turn pivots on a bracket arm extending inwardly from a part-circular plate mounted on the inner periphery of the tire retaining rim.

[0006] Another solution includes a wheel disc between the hub and the outer rim. For example, U.S. Patent No. 1,808,886 to Courtney also discloses a wheel disc or sidewall between the hub and the rim. The wheel disc is engaged by studs that protrude from the hub and extend obliquely from the outer flange to the hub. The wheel disc assists the tire and rim by resisting any tendency to become laterally indicated due to stresses generated while the wheel is turning.

[0007] U.S. Patent No. 1,979,935 to Henap discloses a hydraulic spoke wheel. Each hydraulic spoke includes a telescopic section in the form of an outer section and an inner section. The outer section has a stud protruding from one end. The inner section extends from the outer section and is provided with a trunk at the end of its extension.

[0008] U.S. Patent No. 6,041,838 to Al-Sabah discloses a wheel including spokes positioned in spaced relation to one another. Each spoke has a first end connected to the rim and a second end connected to a plate member end of a hub plate member in an offset position offset from its respective radial axis. The offset position of each spoke is further defined by each spoke being connected to an end of a corresponding one of the plate members at a predetermined angle (e.g., less than 90 degrees) to the radial axis of the corresponding one of the plate members end and defining an operational offset spoke axis that intersects the radial axis of the plate member end at the predetermined angle.

[0009] U.S. Patent No. 6,698,480 to Cornellier discloses a shock absorbing spoke, each having a central cylindrical tube. Each tube includes an inner cap having an aperture and an outer cap having an aperture. Each spoke has an inner piston, a rod with an aperture, and a pin. The pin pivotally couples one of the spokes to the hub. Each spoke has an outer piston, a rod with an aperture, and a pin. The pin pivotally couples one of the spokes to the rim assembly. The inner and outer pistons divide the space within each tube into an inner chamber, an outer chamber, and a center chamber.

[0010] U.S. Patent No. 1,650,609 to Cravens discloses a resilient wheel and more particularly a resilient disc wheel for a motor vehicle. The resilient wheel provides a simple and efficient disc wheel that can be used in conjunction with a pneumatic or solid tire and that will absorb road shocks and vibrations by virtue of its own inherent elasticity in performing its function without reliance on tire elasticity.

[0011] U.S. Patent No. 1,295,378 to Smith et al. relates to wheels, and more particularly to improvements in resilient wheels. The wheel provides a puncture-resistant wheel whose component connections, organization and construction eliminate the need for conventional pneumatic or rubber tires while providing the desired degree of resiliency between the tire and wheel structure.

[0012] U.S. Patent No. 967,515 to Gruss et al. relates to wheels and, more particularly, to cushioning devices. The wheel provides a practical, resilient, non-puncturable wheel, particularly suitable for automobiles, and is designed to eliminate the need for the inflatable rubber inner tube currently used.

[0013] Despite advances in pneumatic and non-pneumatic tire wheels, there remains a need for improved wheel technology, particularly for large construction or mining vehicles, for example. The expense of wheel replacement and the downtime experienced during wheel replacement can significantly increase the expense of a construction or mining project. Summary of the invention

[0014] A wheel assembly to be coupled to a wheel hub of a vehicle may include an inner rim to be coupled to the wheel hub of the vehicle and an outer rim surrounding the wheel hub. The wheel assembly may also include a plurality of gas springs operably coupled between the inner rim and the outer rim to provide a gas suspension that allows relative movement between the inner rim and the outer rim. The wheel assembly may also include a sidewall cover assembly, the sidewall cover assembly may include an inner sidewall cover coupled to the inner rim and extending radially outward toward the outer rim. The sidewall cover assembly may also include an outer sidewall cover coupled to the outer rim and extending radially inward toward the inner rim and in a sliding overlapping relationship with the inner sidewall cover, thereby allowing relative movement between the inner sidewall cover and the outer sidewall cover.

[0015] For example, the inner side wall cover may comprise an inner side wall panel and an inner wiper device extending from the inner side wall panel towards the outer side wall cover and in sliding contact with the outer side wall cover. The inner wiper device may comprise an elastic wiper blade.

[0016] The outer side wall cover may comprise an outer side wall panel and an outer wiper device extending from the outer side wall panel towards the inner side wall cover and in sliding contact with the inner side wall cover. The outer wiper device may comprise an elastic wiper blade.

[0017] The wheel assembly may include an outer ring and an inner ring, the outer ring being coupled to the outer rim and extending radially inwardly therefrom, the inner ring being coupled to the inner rim, extending radially outwardly therefrom and defining a closable gap with an adjacent portion of the outer ring to define a mechanical stop to limit relative movement of the inner rim and the outer rim. For example, the plurality of gas springs may have an operating stroke that allows the outer ring and the inner ring to define a mechanical stop.

[0018] For example, the plurality of gas springs may be arranged in pairs on opposite sides of the outer ring.The plurality of gas springs may radiate outwardly from the inner rim to the outer rim.

[0019] One aspect of the method relates to a method of assembling a wheel assembly to be coupled to a wheel hub of a vehicle. The method may include coupling a plurality of gas springs between an inner rim and an outer rim to be coupled to the wheel hub to provide a gas suspension that allows relative movement between the inner rim and the outer rim. The method may also include coupling an inner sidewall cover of a sidewall cover assembly to the inner rim and extending the inner sidewall cover radially outward toward the outer rim. The method may also include coupling an outer sidewall cover of the sidewall cover assembly to the outer rim and extending the outer sidewall cover radially inward toward the inner rim and bringing the outer sidewall cover into a sliding overlapping relationship with the inner sidewall cover, thereby allowing relative movement between the inner sidewall cover and the outer sidewall cover. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] Figure 1 is a side view of a vehicle having a wheel assembly according to an embodiment.

[0021] Figure 2 is a perspective view of a wheel assembly according to an embodiment.

[0022] Figure 3 yes Figure 2 Another perspective view of the wheel assembly.

[0023] Figure 4 yes Figure 2 Another perspective view of the wheel assembly.

[0024] Figure 5 yes Figure 2 A perspective view of a portion of a wheel assembly.

[0025] Figure 6 yes Figure 2 A perspective view of the inner rim, wheel disc and attachment bracket of the wheel assembly.

[0026] Figure 7 is a perspective view of a portion of a wheel assembly including a tread assembly and a removable sidewall according to an embodiment.

[0027] Figure 8 is a perspective view of a portion of a wheel assembly according to an embodiment.

[0028] Fig. 9 is another perspective view of a portion of a wheel assembly according to an embodiment.

[0029] Fig.10 yes Fig. 9 A perspective view of a tread member support.

[0030] Fig.11 yes Fig. 9 A perspective view of a portion of a tread assembly.

[0031] Fig.12 yes Fig. 9 A perspective view of a tread member of a tread assembly.

[0032] Fig.13 is a perspective view of an inner clamping member of a wheel assembly according to an embodiment.

[0033] Fig.14 is a perspective view of an outboard clamping member of a wheel assembly according to an embodiment.

[0034] Fig.15 is a perspective view of a portion of a wheel assembly including an outboard clamping member according to an embodiment.

[0035] Fig.16 is a cross-sectional view of a portion of an outer rim, retention features, and a tread assembly according to an embodiment.

[0036] Fig.17 is a cross-sectional view of a portion of a tread assembly according to another embodiment.

[0037] Fig.18 is a perspective view of a wheel assembly according to another embodiment.

[0038] Fig.19 yes Fig.18 Schematic diagram of the lateral stop.

[0039] Fig. 20 is a schematic diagram of a portion of a wheel assembly including a local controller for controlling an operational response of a gas spring, according to an embodiment.

[0040] Fig.21 is a schematic diagram of a portion of a wheel assembly including a local controller for controlling an operational response of a gas spring according to another embodiment.

[0041] Fig. 22 is a perspective view of an inner removable side wall of a wheel assembly according to an embodiment.

[0042] Fig.23 is a perspective view of an outer removable side wall of a wheel assembly according to an embodiment.

[0043] Fig.24 is a perspective view of a wheel assembly according to another embodiment.

[0044] Fig.25 is a schematic diagram of a portion of a wheel assembly including a sensor for measuring a distance between an inner rim and an outer rim according to another embodiment.

[0045] Fig.26 is a side cross-sectional view of a portion of a wheel assembly according to another embodiment.

[0046] Fig. 27 yes Fig.26 A perspective cutaway view of this portion of the wheel assembly.

[0047] Fig.28 yes Fig. 27 A perspective view of the cover ring and flexible seal.

[0048] Fig.29 yes Fig. 27 Another perspective view of the cover ring and flexible seal.

[0049] Fig.30 yes Fig. 27 A perspective view of a flexible seal.

[0050] Fig.31 yes Fig. 27 Another perspective view of the cover ring and flexible seal.

[0051] Fig.32 is a perspective view of a portion of a wheel assembly according to another embodiment.

[0052] Fig.33 yes Fig.32 A perspective view of the inboard lateral stop of the wheel assembly.

[0053] Fig.34 is a perspective view of a wheel assembly according to another embodiment.

[0054] Fig.35 yes Fig.34 A perspective view of a portion of a wheel assembly of (and without the lightening openings in the inner ring).

[0055] Fig.36 yes Fig.35 A side view of this portion of the wheel assembly.

[0056] Fig.37 yes Fig.34 A perspective view of an inner lateral stop and an outer lateral stop of a wheel assembly.

[0057] Fig.38 is a perspective view of a portion of a wheel assembly according to an embodiment.

[0058] Fig.39 yes Fig.38 A perspective view of a portion of a wheel assembly.

[0059] Fig.40 yes Fig.38 A perspective view of another portion of the wheel assembly.

[0060] Fig.41 is a perspective view of a wheel assembly according to an embodiment.

[0061] Fig.42 yes Fig.41 A side view of a portion of a wheel assembly.

[0062] Fig.43 yes Fig.41 Another side view of a portion of a wheel assembly.

[0063] Fig.44 yes Fig.41 A perspective view of a portion of a wheel assembly.

[0064] Fig.45 yes Fig.41 An enlarged cross-sectional view of a portion of a lateral stop of a wheel assembly.

[0065] Fig.46 yes Fig.41 An enlarged perspective view of another portion of the lateral stop of the wheel assembly.

[0066] Fig.47 yes Fig.46 Bottom perspective view of the lateral stop.

[0067] Fig.48 yes Fig.41 A top perspective view of a portion of the elastomeric body of a lateral stop of a wheel assembly.

[0068] Fig.49 yes Fig.41 A top perspective view of another portion of the elastomeric body of the lateral stop of the wheel assembly.

[0069] Fig.50 is a perspective view of a wheel assembly according to another embodiment.

[0070] Fig.51 According to an embodiment, a flexible seal is provided. Fig.50 A cross-sectional view of a portion of a wheel assembly.

[0071] Fig.52is a perspective view of a wheel assembly according to another embodiment.

[0072] Fig.53 yes Fig.52 Another perspective view of the wheel assembly.

[0073] Fig.54 yes Fig.52 An enlarged perspective view of a portion of a wheel assembly.

[0074] Fig.55 yes Fig.52 A perspective view of the cylinder of the lateral stop of the wheel assembly.

[0075] Fig.56 is a perspective cross-sectional view of a wheel assembly according to an embodiment.

[0076] Fig.57 yes Fig.56 Another perspective cutaway view of a wheel assembly.

[0077] Fig.58 is a perspective cross-sectional view of a portion of a wheel assembly according to an embodiment.

[0078] Fig.59 is a schematic diagram of a sidewall cover assembly according to an embodiment.

[0079] Fig.60 is a schematic diagram of a sidewall cover assembly according to another embodiment. DETAILED DESCRIPTION

[0080] The present invention will now be described more fully below with reference to the accompanying drawings. However, the present invention can be implemented in many different forms and should not be construed as being limited to the embodiments set forth herein. On the contrary, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the present invention to those skilled in the art. Throughout the text, the same reference numerals represent the same elements, and in alternative embodiments, apostrophes are used to indicate similar elements.

[0081] First refer to Figures 1 to 5 , a wheel assembly 30 to be coupled to a wheel hub 21 of a vehicle 20 includes an inner rim 31 to be coupled to the wheel hub of the vehicle. The inner rim 31 can be coupled to the wheel hub 21 of the vehicle 20 using fasteners through fastener receiving passages 24 within an inwardly extending flange ring 25. Exemplarily, the flange ring 25 is laterally centered within the inner rim 31, but may be positioned in another arrangement based on the desired mounting arrangement with the wheel hub 21. Other coupling means may be used to couple the inner rim 31 to the wheel hub 21.

[0082] The wheel assembly 30 also includes an outer rim 33 surrounding the inner rim 31. The diameter of the outer rim 33 can be at least 3.5 feet, and more specifically at least 4 feet. Those skilled in the art will appreciate that using a diameter of at least 3.5 feet, the wheel assembly 30 (and more specifically the outer rim 33) can be particularly advantageous for use with relatively large or heavy machines, such as earthmoving equipment and mining equipment. A typical overall outer diameter of such a wheel assembly is 100 inches or more. The outer rim 33 can have a thickened portion 38 along its inner circumference. The thickened portion 38 can be provided by welding a separate reinforcement ring in an appropriate position, or the thickened portion 38 can be formed integrally with the outer rim 33, for example.

[0083] In addition, refer to Figure 6 , the wheel disc 40 is coupled to the inner rim 31 and defines a closable gap 41 together with an adjacent inner portion of the outer rim 33. The wheel disc 40 also includes weight-reducing openings 43 therein. The weight-reducing openings 43 each exemplarily have a generally rounded or circular shape. The weight-reducing openings 43 may have other shapes, such as elliptical, hexagonal, and / or profiles for reducing stress. Those skilled in the art will appreciate that reducing weight may improve the fuel efficiency of the vehicle 20 and / or may increase the life of the wheel assembly 30.

[0084] The wheel disc 40 also includes spaced apart thickened wall portions 42. The spaced apart thickened wall portions 42 can be provided on both the inside surface and the outside surface of the wheel disc 40. Each thickened wall portion 42 can provide increased strength or support as a connection point or attachment point, and / or receive increased stress thereat, as will be described in further detail below. The thickened wall portions 42 can be provided, for example, by welding additional metal bodies in appropriate locations, or they can be formed integrally with the wheel disc 40. Those skilled in the art will appreciate that the thickened wall portions 42 can be in the form of solid extensions of the wheel disc 40 (i.e., they are formed integrally with the wheel disc and / or constructed by the wheel disc) and / or can be in the form of discrete bodies, for example, used as mechanical reinforcements.

[0085] The inner rim 31, the outer rim 33 and the wheel disc 40 may be formed of a high strength and strong material such as steel. As will be appreciated by those skilled in the art, other materials may also be used.

[0086] The gas springs 50 are operably coupled between the inner rim 31 and the outer rim 33. Each gas spring 50 may be, for example, a double-acting gas spring and include a double-acting cylinder 51 and an associated piston 52. Of course, in some embodiments, each gas spring 50 may be a single-acting gas spring. More than one type of gas spring may be used. The gas spring 50 may be, for example, an air spring and / or a nitrogen spring. The gas spring 50 may also include other gases.

[0087] Exemplarily, the gas springs 50 are arranged in pairs on opposite sides of the wheel disc 40. More specifically, the gas springs 50 diverge outwardly from the inner rim 31 to the outer rim 33. A corresponding attachment bracket 53 for each gas spring 50 is coupled to a corresponding thickened wall portion 42 of the wheel disc 40, for example, adjacent to the inner rim 31. Each attachment bracket 53 may include a generally U-shaped or V-shaped base bracket that receives an end of a piston 52 therein (e.g., between arms of the U-shaped or V-shaped bracket). Fasteners fasten the ends of the pistons 52 of the gas springs 50 to the base brackets, and thus, each gas spring is coupled adjacent to a corresponding thickened wall portion 42 of the wheel disc 40 and adjacent to the inner rim 31. Similar attachment brackets 53 are coupled to the outer rim 33 adjacent to the inner and outer side surfaces. Thus, the gas springs 50 are pivotably coupled between the inner rim 31 and the outer rim 33.

[0088] As will be appreciated by those skilled in the art, the gas spring 50 provides a gas suspension for relative movement between the inner rim 31 and the outer rim 33. The gas spring 50 has an operating stroke that allows the disc 40 to define a mechanical stop. In other words, the gas spring 50 keeps the outer rim 33 spaced apart from the inner rim 31. However, if the pressure on any of the gas springs 50 causes the gas spring to reach its limit under load or the gas spring fails, the disc 40 can act as a mechanical stop to limit the relative movement of the inner rim 31 and the outer rim 33. In other words, the disc 40 and the gas spring 50 can be considered to provide a run-flat capability.

[0089] The initial charge pressure of the gas spring 50, for example, when the gas spring is in the form of a double-acting gas spring, will now be described relative to the initial pressure in the wheel assembly 30 when little or no external load (i.e., freewheel) is applied to the wheel assembly 30. Specifically, the chamber associated with the piston side of the cylinder 51 is typically smaller than the chamber associated with the full bore side of the cylinder (e.g., about 10% smaller). Therefore, when the piston 52 is centered within the cylinder 51 so that there is a relatively equivalent stroke in tension and compression, the pressure of the piston side chamber is higher than the pressure of the full bore side chamber (e.g., about 10% higher).

[0090] Thus, although isobaric filling of the double-acting cylinder 51 would be appropriate, the double-acting cylinder 51 causes the piston 52 to be offset, which in turn causes an offset force to be applied to assemble the gas spring 50 within the wheel assembly 30. To accomplish this, the inner rim 31 and the outer rim 33 may be temporarily secured in a rigid fixture. However, the use of a rigid fixture makes it increasingly difficult to replace the gas spring 50 in the field. Therefore, to address the issue of making it easier to replace the gas spring 50 in the field, a welding ring may be coupled to the inner rim 31 and the outer rim 33 and to a turnbuckle to temporarily lock the inner rim and the outer rim in place. As will be appreciated by those skilled in the art, a similar arrangement may also be used in a workshop.

[0091] The result is therefore a prestressed suspension of the inner rim 31 to the outer rim 33. The prestress can ensure that the lateral stops 44, 45 (described below) are inactive or under pressure. The suspension can be pre-compressed at different filling pressures. Although tension suspension and compression suspension can be considered equivalent, tension suspension can be more advantageous than compression suspension, as will be understood by those skilled in the art.

[0092] Another assembly technique may include applying a higher filling pressure at the piston side (e.g., about 10% higher) to center the piston 52 at about the half-stroke position. This results in no initial load on the gas spring 50 at the wheel assembly 30 and facilitates assembly without being temporarily fixed in a fixture. Therefore, the wheel assembly 30 can be considered neither prestressed nor pre-compressed, but neutral. For example, a full-bore side chamber pressure higher than the piston side chamber pressure (e.g., about 10% higher) can be applied. Gas can be released from the full-bore side chamber until the piston 52 becomes centered relative to the full stroke. Alternatively, a piston side chamber pressure higher than the full-bore side chamber pressure (e.g., about 10% higher) can be applied. Releasing gas from the cylinder 51 can be considered easier than surcharging, however, this uses more gas (e.g., nitrogen) compared to other solutions, resulting in increased costs.

[0093] The wheel assembly 30 also includes an inner lateral stop 44 carried by the inner side surface of the outer rim 33. More specifically, the inner lateral stop 44 is positioned adjacent to the thickened wall portion 42. The wheel assembly 30 also includes an outer lateral stop 45 carried by the outer side surface of the outer rim 33. Similar to the inner lateral stop 44, the outer lateral stop 45 is adjacent to the thickened wall portion 42. Each thickened wall portion 42 is positioned between a pair of inner and outer lateral stops 44, 45. The inner and outer lateral stops 44, 45 together with the outer rim 33 can be conceptually considered to be in the form of an L-shaped bracket. Exemplarily, the inner and outer lateral stops 44, 45 each have a support plate 61 (e.g., which has a rectangular shape) that is transverse to the outer rim 33 and each have a triangular side member 62.

[0094] As will be appreciated by those skilled in the art, the inner and outer lateral stops 44, 45 cooperate to limit the relative lateral movement of the wheel disc 40 and the outer rim 33. In other words, for example, turning of the vehicle 20 can cause the wheel disc 40 to move laterally relative to the outer rim 33. The inner and outer lateral stops 44, 45 can limit the amount of lateral movement of the wheel disc 40 relative to the outer rim 33, thereby maintaining the structural integrity of the wheel assembly 30. Of course, the inner and outer lateral stops 44, 45 include other and / or additional components or elements that cooperate to limit the relative lateral movement of the wheel disc 40 and the outer rim 33.

[0095] Now refer to Figures 7 to 16 The wheel assembly 30 illustratively includes a tread assembly 70 carried by the outer rim 33. Each tread assembly 70 includes a tread component support 71. Each tread component support 71 can be a tread component having openings 69a, 69b ( Fig.10 ) and can be coupled to the outer circumference of the outer rim 33. In other embodiments, one or more of the tread component supports 71 can be flat plates. The central one of the openings 69b can receive a pin 83 therein, as will be described in further detail below. In some embodiments, the tread component supports 71 may not be metal (e.g., steel). Those skilled in the art will appreciate that, given the arcuate shape of the tread component supports 71, several tread assemblies 70 are coupled around the outer rim 33 in an end-to-end relationship.

[0096] The tread member 72 is coupled or bonded (e.g., glued, fastened, etc.) to the tread member support 71, and the clamping device 73 removably secures the tread member support to the outer rim 33. There may be more than one tread member 72 bonded to the tread member support 71. The tread member 72 includes an elastomeric body 85 having a tread pattern 86 defined on its outer surface. The elastomeric body 85 may include rubber or other materials, which may be selected based on desired friction, traction or other properties (e.g., based on the use of the vehicle 20). In other embodiments, the material of the tread member 72 may be metal, such as steel. The tread pattern 86 may be similarly selected based on desired traction or other properties (e.g., based on the use of the vehicle 20). Also, referring briefly to Fig.17 In another embodiment, each tread member 72' and tread member support 71' may include a common material that is integrally formed as a unitary unit, which may or may not be metal, such as steel. In other words, each tread member 72' and tread member support 71' defines a single unit or body of the same material (e.g., an all-metal tread member support and tread member).

[0097] More details of the clamping device 73 will now be described. The clamping device 73 illustratively includes inner clamping members 74 coupled to the inner side of the outer rim 33. The inner clamping members 74 each have a first slotted recess 75 that receives an adjacent portion of the tread member support 71. The inner clamping members 74 are removably coupled to the inner side of the outer rim 33. The inner clamping members 74 are illustratively arranged in an end-to-end relationship, and the inner clamping members 74 are each coupled to an adjacent corresponding portion of the outer rim 33. In some embodiments, the inner clamping members 74 may be fixed (e.g., welded or fixedly coupled) to the inner side of the outer rim 33, and / or a single inner clamping member may be used.

[0098] The inner clamping member 74 is coupled to the inner side of the outer rim 33 by a fastener 79a (e.g., a threaded fastener) to facilitate removal and replacement, for example, when the tread member 72 is worn or it is desired to replace the tread member. The threaded fastener 79a can extend through the opening 89 in the inner clamping member 74 and engage the corresponding threaded opening 81a in the outer rim 33.

[0099] The clamping device 73 also illustratively includes an outer clamping member 76 coupled to the outer side of the outer rim 33. Similar to the inner clamping member 74, the outer clamping members 76 each have a second slotted recess 77 that receives an adjacent portion of the tread member support 71 therein. The outer clamping members 76 are removably coupled to the outer side of the outer rim 33. The outer clamping members 76 are illustratively arranged in an end-to-end relationship, and each of the outer clamping members 76 is coupled to an adjacent corresponding portion of the outer rim 33. In some embodiments, a single outer clamping member 76 may be coupled to the outer side of the outer rim 33 and extend along the circumference of the outer rim.

[0100] Outer clamping member 76 is coupled to the outer side of outer rim 33 by fasteners (e.g., threaded fasteners) to facilitate removal and replacement, for example, when tread member 72 is worn or when it is desired to replace the tread member. The threaded fasteners can extend through openings 78 in outer clamping member 76 and engage corresponding threaded openings 81 b in outer rim 33.

[0101] Adjacent portions of the tread member support 71 and the outer rim 33 (e.g., along the outer circumference) define a retaining feature therebetween. The retaining feature is illustratively in the form of or includes a pin 83 carried by the outer rim 33 and a pin receiving opening 84 in the tread member support 71. The pin 83 and the pin receiving opening 84 can advantageously prevent relative movement between the tread member support 71 and the outer rim 33, and, for example, also facilitate replacement of the tread member 72 (e.g., easy alignment), thereby reducing downtime of the vehicle 20.

[0102] Now briefly refer to Fig.18 and Fig.19 In another embodiment, the inner and outer lateral stops 44", 45" are biased toward the wheel disc 40". More specifically, the inner and outer lateral stops 44", 45" each include an arm 46" extending radially inward from the inner inner surface and the outer inner surface of the outer rim 33". A lateral arm 47" is connected to the end of each arm 46". Each lateral arm 47" has a plug 48", which is biased toward the wheel disc 40" by a biasing member 49" such as a spring (e.g., a coil spring). Other biasing devices may be used.

[0103] Now refer to Fig. 20, one or more of the gas springs 50 may have a controllable response. For example, the gas spring 50 may have one or both of a controllable gas pressure and a controllable gas volume. Any number of gas springs 50 may have a controllable response. By having a controllable response, each of the gas springs 50 may be operated or controlled, for example, relative to certain operating conditions and / or environments as explained in further detail below. More specifically, the wheel assembly 30 may include a local controller 87 (e.g., including a processor and / or circuit) coupled to the gas spring 50. The local controller 87 may be coupled to any number of gas springs 50. The local controller 87 may be carried within the outer rim 33 (e.g., carried inside the outer rim), or carried by the wheel disc 40. The local controller 87 may be carried by other elements of the wheel assembly 30. The local controller 87 may also include corresponding actuators and / or valves to control the response of the gas spring 50, and cooperate with the accumulator 91 also coupled to the gas spring to serve as a pressure and / or volume storage container for the gas spring.

[0104] The wheel assembly 30 may also include a local sensor 88 coupled to the local controller 87. The local controller 87 may control (e.g., monitor and / or adjust) the operational response of the gas spring 50 based on the local sensor 88. For example, the local controller 87 may adjust the pressure or volume of the gas spring 50 without controlling the operation (e.g., extension / retraction) of the gas spring. For example, alternatively or additionally, the local controller 87 may also adjust the operation (e.g., extension / retraction) of the gas spring 50.

[0105] The local sensor 88 can be, for example, an acceleration sensor, and cooperates with the local controller 87 to control a controllable response of the gas spring 50 based on the sensed acceleration (e.g., braking, turning, etc.). The local sensor 88 can be another type of sensor, for example, a force sensor. There can be more than one local sensor 88. In some embodiments, the local controller 87 can cooperate with the local sensor 88 to generate a notification, for example, when a sensed value exceeds a threshold. The notification can be communicated within the vehicle 20 (e.g., in the cab) or away from the vehicle. In other words, the local controller 87 can cooperate with the local sensor 88 independently of the operational response of the gas spring 50 or without controlling the operational response of the gas spring 50.

[0106] Now briefly refer to Fig.21In another embodiment, the remote controller 92'" can be carried away from the wheel assembly 30, for example, carried in a wheel well of the vehicle 20 or carried in a truck cab. The remote controller 92'" can cooperate with the local sensor 88'" or other sensors (for example, away from the wheel assembly 30). The remote controller 92'" can also cooperate with the local controller 87'" to achieve changes in the operational response of the gas spring 50'"'. Wiring from the remote controller 92'" can extend to the local controller 87'" and / or the remote controller can communicate wirelessly with the local controller.

[0107] Those skilled in the art will appreciate that the local controller 87 controls the operational response of the gas springs 50 while the wheel assembly 30 is rolling. For example, if the vehicle 20 makes a relatively sharp turn or applies brakes during its motion, the local controller 87 can independently control the operational response of each or selected gas spring 50 based on the turn or brake (e.g., increase the pressure in the gas spring of the front wheel assembly). Other motions of the vehicle 20 may cause changes in the operational response, such as failure of any gas spring 50, debris in the tread member 72, and / or contact of the wheel disc 40 with the outer rim 33, for example.

[0108] Now refer to Fig. 22 and Fig.23 , the wheel assembly 30 may include inner and outer removable sidewalls 93, 94. The inner and outer removable sidewalls 93, 94 are each illustratively in the form of a rounded or circular cover carried by the outer rim 33. More specifically, the inner and outer removable sidewalls 93, 94 each have an opening 95, 105 therein to allow, for example, the wheel assembly 30 to be coupled to the hub 21. Respective flanges 103, 106 extend inwardly within the openings 95, 105. The inner and outer removable sidewalls 93 and 94 may each be coupled to the inner and outer sides of the outer rim 33 by fasteners 97a, 97b and also coupled to the inner rim 31 by fasteners 107a, 107b. The fasteners 97a, 97b may be received by fastener receiving passages along the outer circumference of each of the inner and outer removable sidewalls 93, 94 and fastened to corresponding, respectively aligned threaded passages 98a, 98b in the outer rim 33. The threaded passages 98a, 98b in the outer rim 33 form an inner row of second threaded passages which, together with the outer row of threaded passages 81a, 81b, are used to fasten the outer rim 33 with the aid of the fastener 79a ( Figure 7 ) Fix the clamping device 73 to the outer rim.

[0109] Now refer to Fig.24In another embodiment, the outer removable sidewall 94"" can have a removable inner panel 101"" that allows access to the interior of the wheel assembly 30"" (e.g., the inner rim) when the removable inner panel 101"" is removed by corresponding fasteners 102"". Similar to the outer removable sidewall described above, the outer sidewall 94"" is coupled to the outer rim 33"" by fasteners 97b"" within or near the outer clamping member 76"" (which is also secured to the outer rim by fasteners 79b"". The elements shown but not specifically described are similar to those described above.

[0110] As will be appreciated by those skilled in the art, the inner and outer removable sidewalls 93, 94 can be particularly useful in reducing the amount of dust and / or debris within the interior of the wheel assembly 30 (e.g., between the inner rim 31 and the outer rim 33). Accordingly, the components of the wheel assembly 30 (e.g., the wheel disc 40 and the gas spring 50) can have enhanced protection from damage, such as from environmental factors (e.g., rocks, dust, dirt, water, etc.), and can thereby extend their service life. In some embodiments, the wheel assembly 30 may not include the inner and outer removable sidewalls 93, 94.

[0111] Now refer to Fig.25 In another embodiment, the sensors 188a, 188b sense the relative motion, for example, by sensing the distance between the inner rim 131 and the outer rim 133. More specifically, the sensors 188a, 188b may be in the form of a three-axis accelerometer. Of course, the sensors 188a, 188b may be other types of sensors, for example, laser distance sensors, ultrasonic sensors, linear variable differential transformer (LVDT) sensors, and / or other contact or non-contact displacement sensors.

[0112] When the sensors 188a, 188b are in the form of three-axis accelerometers, one of the accelerometers is carried by the inner rim 131 defining an inner accelerometer, while the other accelerometer is carried by the outer rim 133 defining an outer accelerometer. The inner and outer accelerometers 188a, 188b are aligned by their axes so that relative motion of the inner rim 131 and the outer rim 133 can be converted as sensed accelerations (e.g., by integrating each acceleration), for example, by a distance measurement circuit 187 coupled to the accelerometers 188a, 188b.

[0113] Each of the sensors 188a, 188b may be different from one another. For example, an ultrasonic sensor may be used with the internal and external accelerometers 188a, 188b to sense or measure displacement (e.g., tangential to the internal and external accelerometers). Of course, a laser distance sensor may be used as an alternative to an ultrasonic sensor or in combination with an ultrasonic sensor and / or the internal and external accelerometers 188a, 188b. The measurement circuit 187 may be carried by the wheel assembly, the vehicle, or remote from the vehicle.

[0114] A temperature sensor 188c may be carried by the outer rim 133 (e.g., carried within the inner surface of the outer rim or on the inner surface of the outer rim) and coupled to the measurement circuit 187 to sense the temperature within the wheel assembly, for example, when a cover or inner or outer removable sidewall is used. Alternatively or additionally, a humidity sensor 188d may be carried by the outer rim 133 (e.g., carried within the inner surface of the outer rim or on the inner surface of the outer rim) and coupled to the measurement circuit 187 to sense the humidity within the wheel assembly, for example, when a cover or inner or outer removable sidewall is used. Data representing humidity, acceleration or distance data (e.g., raw data or processed data) and / or data representing temperature may be remotely communicated from the wheel assembly or vehicle via a wireless transmitter 190 coupled to the measurement circuit 187 for downstream processing.

[0115] Now refer to Figure 26 to Figure 31 In another embodiment, the wheel assembly 230 includes a rigid inner cover ring 293 coupled to the inner side of the outer rim 233, for example, by fasteners 207a. The rigid inner cover ring 293 extends radially inwardly toward the inner rim 231. More specifically, the rigid inner cover ring 293 and the inner rim 231 define a radially and axially extending inner gap. A flexible inner seal 209a, for example, in the form of an inner bellows seal, is coupled between the rigid inner cover ring 293 and the inner rim 231, for example, by corresponding fasteners 208a to couple to the inner rim (e.g., used with a clamping device 212a, such as a metal band or other material). The flexible inner seal 209a closes the radially and axially extending inner gap and allows relative movement of the inner rim 231 and the outer rim 233. Exemplarily, the inner bellows seal 209a has a Z-shaped cross-section. The flexible inner seal 209a may be, for example, different types of flexible seals and may have cross-sections of different shapes. The flexible inner seal 209a may include rubber and / or elastomeric materials. The flexible inner seal 209a may include other materials and / or additional materials.

[0116] The wheel assembly 230 also includes a rigid outer cover ring 294 coupled to the outer side of the outer rim 233, for example, by fasteners 207b. The rigid outer cover ring 294 extends radially inwardly toward the inner rim 231. More specifically, the rigid outer cover ring 294 and the inner rim 231 define a radially and axially extending outer gap. A flexible outer seal 209b, for example in the form of an outer bellows seal, is coupled between the rigid outer cover ring 294 and the inner rim 231, for example, by corresponding fasteners 208b (e.g., and corresponding clamping devices 212b). The flexible inner seal 209b closes the radially and axially extending outer gap and allows relative movement of the inner rim 231 and the outer rim 233. Exemplarily, the outer bellows seal 209a has a Z-shaped cross-section. The flexible outer seal 209b, for example, can be a different type of flexible seal and can have a cross-section of different shapes.

[0117] Furthermore, a corresponding pleated cover 210 (eg, a bellows) is coupled to each gas spring 250. Specifically, the pleated cover 210 covers the piston so that the piston can be kept free from dust, dirt, and / or debris ( Fig.26 ). As will be appreciated by those skilled in the art, reducing the amount of dust, dirt, and / or debris that comes in contact with the piston can increase the operating life of the gas spring 250.

[0118] The flexible outer seal 209b may include rubber and / or elastomeric materials. The flexible outer seal 209b may include other materials and / or additional materials. In some embodiments, the rigid outer cover ring 294 and the flexible outer seal 209b may not be used. The elements shown but not specifically described are similar to those described in the above embodiments, so there is no need to repeat their description.

[0119] Now especially refer to Fig.31 , similar to the above Figure 22 to Figure 24 In the depicted embodiment, a rigid removable interior or inner panel 201 may be carried within a rigid outer cover ring 294 (e.g., secured to the wheel assembly via fasteners 297b) to allow access to the interior of the wheel assembly 230 (e.g., the inner rim) when the rigid removable interior or inner panel 201 is removed via corresponding fasteners 202. An access port or removable cover 211a is spaced within the rigid outer cover ring 294. For example, the removable cover 211a may be clear acrylic to allow visual inspection within the wheel assembly without removing the rigid removable interior panel 201 and / or to allow easy access to, for example, sensors, controllers, and / or other circuitry, as described above. For example, a similar device including an access port or removable cover 211b may be used as a rigid inner cover ring 294, as described above ( Figure 26 to Figure 27 ). Inlet ports 211a, 211b may not be used in all embodiments.

[0120] The embodiments of the wheel assembly 30 described herein can be particularly advantageous relative to conventional pneumatic tires, for example, particularly on relatively large vehicles (e.g., heavy machinery). For example, conventional pneumatic tires for heavy machinery have relatively high costs and can have relatively short service lives in certain environments. In addition, particularly for heavy machinery, failure of conventional tires can result in an increased probability of damage to the heavy machinery as a function of time. Even further, failure of conventional tires can cause the vehicle 20 to be inoperable or unusable for a considerable period of time, resulting in financial losses and productivity losses, particularly for certain types of vehicles or heavy machinery that operate around the clock.

[0121] The wheel assembly 30 can address these shortcomings of conventional tires. More specifically, the wheel assembly 30 can have lower operating costs and have enhanced performance (e.g., by virtue of the controllable operating response of the gas spring 50). Additionally, the wheel assembly 30 can be field repairable, meaning that the tread member 72 can be replaced in the field. For example, in the event of a gas spring 50 failure, repairs can also be performed in the field.

[0122] One aspect of the method relates to a method of manufacturing a wheel assembly 30 to be coupled to a wheel hub 21 of a vehicle 20. The method includes operably coupling a plurality of gas springs 50 between an inner rim 31 of a wheel hub 21 to be coupled to the vehicle 20 and an outer rim 33 surrounding the inner rim. The method also includes mounting a plurality of tread assemblies 70 to the outer rim 33. Each tread assembly 70 may be mounted by bonding at least one tread member 72 to a tread member support 71 and positioning a clamping device 73 to removably secure the tread member support to the outer rim 33.

[0123] Another aspect of the method relates to a method of manufacturing a wheel assembly 30 to be coupled to a wheel hub 21 of a vehicle 20. The method includes operably coupling a plurality of gas springs 50 between an inner rim 31 of a wheel hub 21 to be coupled to the vehicle 20 and an outer rim 33 surrounding the inner rim 31 to provide a gas suspension for relative movement between the inner rim and the outer rim. The method also includes coupling a wheel disc 40 to the inner rim 31, the wheel disc 40 and an adjacent inner portion of the outer rim 33 defining a closable gap 41 to define a mechanical stop to limit relative movement of the inner rim and the outer rim.

[0124] Another aspect of the method relates to a method of manufacturing a wheel assembly 30 to be coupled to a wheel hub 21 of a vehicle 20. The method includes operably coupling a plurality of gas springs 50 between an inner rim 31 of a wheel hub 21 to be coupled to the vehicle 20 and an outer rim 33 surrounding the inner rim to provide a gas suspension for relative movement between the inner rim and the outer rim. The method also includes coupling a wheel disc 40 coupled to the inner rim 31 and defining a closable gap 41 with an adjacent inner portion of the outer rim 33. The method may also include positioning a plurality of inner lateral stops 44 carried by an inner inner surface of the outer rim 33, and positioning a plurality of outer lateral stops 45 carried by an outer inner surface of the outer rim, such that the plurality of inner lateral stops and the plurality of outer lateral stops cooperate to limit relative lateral movement of the wheel disc 40 and the outer rim.

[0125] Another aspect of the method relates to a method of manufacturing a wheel assembly 30 to be coupled to a wheel hub 21 of a vehicle 20. The method includes operably coupling a plurality of gas springs 50 between an inner rim 31 of a wheel hub 21 to be coupled to the vehicle 20 and an outer rim 33 surrounding the inner rim. At least one gas spring 50 of the plurality of gas springs has a controllable operational response. The method also includes coupling a local controller 87 to the at least one gas spring 50 to control the operational response of the at least one gas spring.

[0126] Another aspect of the related method relates to a method of operating a wheel assembly 30 to be coupled to a wheel hub 21 of a vehicle 20. The wheel assembly 30 includes an inner rim 31 to be coupled to the wheel hub 21 of the vehicle 20, an outer rim 33 surrounding the inner rim, and a plurality of gas springs 50 operably coupled between the inner rim and the outer rim. At least one gas spring 50 of the plurality of gas springs has a controllable operational response. The method includes operating a local controller 87 coupled to the at least one gas spring 50 to control the operational response of the at least one gas spring.

[0127] Another aspect of the method relates to a method of sensing relative movement (e.g., distance) between an inner rim 131 of a wheel assembly 30 to be coupled to a wheel hub 21 of a vehicle 20 and an outer rim 133 of the wheel assembly. The inner rim 131 is to be coupled to the wheel hub 21 of the vehicle 20 and an outer rim 133 surrounding the inner rim. The wheel assembly 30 includes a plurality of gas springs 50 that are operably coupled between the inner rim 131 and the outer rim 133 and allow relative movement therebetween. The method includes using at least one sensor 188a, 188b to sense relative movement between the inner rim 131 and the outer rim 133 during operation or rolling of the wheel assembly.

[0128] Another aspect of the method relates to a method of manufacturing a wheel assembly 30 to be coupled to a wheel hub 21 of a vehicle 20. The method includes coupling an inner rim 231 to the wheel hub 21 of the vehicle 20 and positioning an outer rim 233 around the inner rim. The method also includes operably coupling a plurality of gas springs 50 between the inner rim 231 and the outer rim 233 to allow relative movement therebetween. The method also includes coupling a rigid inner cover ring 293 to the inner side of the outer rim 233 and extending it radially inward toward the inner rim 231, and coupling a flexible inner seal 209a between the rigid inner cover ring and the inner rim.

[0129] Now refer to Fig.32 In another embodiment of the wheel assembly 330, an outer ring 340 or disk is coupled to an outer rim 333. This is in contrast to the above embodiment in which the ring or disk 40 is coupled to an inner rim 331. In this embodiment, the outer ring 340 coupled to the outer rim 333 and the adjacent inner portion of the inner rim 331 define a closable gap 341 to define a mechanical stop to limit the relative movement of the inner rim and the outer rim. Similar to the above embodiment, the outer rim 333 can have a diameter of at least 3.5 feet.

[0130] Similar to the above embodiment, the outer ring 340 also includes lightening openings 343 therein. The lightening openings 343 each illustratively have a generally rounded or circular shape. The lightening openings 343 may, for example, have another shape, such as an ellipse, a hexagon, and / or a profile for reducing stress.

[0131] The gas springs 350 are operably coupled between the inner rim 331 and the outer rim 333. Each gas spring 350 can be, for example, a double-acting gas spring and include a double-acting cylinder 351 and an associated piston 352. Of course, in some embodiments, each gas spring 350 can be a single-acting gas spring. More than one type of gas spring 350 can be used. The gas spring 350 can be, for example, an air spring and / or a nitrogen spring. The gas spring 350 can also include other gases.

[0132] Exemplarily, the gas springs 350 are arranged in pairs on opposite sides of the outer ring 340. More specifically, the gas springs 350 radiate outwardly from the inner rim 331 to the outer rim 333. A corresponding attachment bracket 353 for each gas spring 350 is coupled to the inner rim 331. Each attachment bracket 353 can include a generally U-shaped or V-shaped base bracket that receives an end of a piston 352 therein (e.g., between arms of the U-shaped or V-shaped bracket). Fasteners secure the ends of the pistons 352 of the gas springs 350 to the base bracket 353. Similar attachment brackets 353 are coupled to the outer rim 333 adjacent to the inner and outer side surfaces. Thus, the gas springs 350 are pivotably coupled between the inner rim 331 and the outer rim 333.

[0133] Similar to the above-described embodiments, as will be appreciated by those skilled in the art, the gas spring 350 provides a gas suspension for relative movement between the inner rim 331 and the outer rim 333. The gas spring 350 has an operating stroke that allows the outer ring 340 to define a mechanical stop. In other words, the gas spring 350 keeps the outer rim 333 spaced apart from the inner rim 331. However, if the pressure on any of the gas springs 350 causes the gas spring to reach its limit under load or the gas spring fails, the outer ring 340 can act as a mechanical stop to limit the relative movement of the inner rim 331 and the outer rim 333. In other words, the outer ring 340 and the gas spring 350 can be considered to provide a run-flat capability. Since the gas spring 350 is similar to the gas spring described with respect to the above embodiments, further details of the gas spring do not need to be described.

[0134] In addition, refer to Fig.33, the wheel assembly 330 also includes an inner lateral stop 344 coupled between the inner side of the outer rim 333 and the inner side of the inner rim 331. More specifically, the inner lateral stop 344 is illustratively in the form of a hinge retainer or a scissor hinge. Each inner lateral stop 344 includes an inner hinge bracket 346a, 346b and an inner elastomeric body 347, such as a polyurethane body, carried by the hinge bracket adjacent to the outer rim 333. More specifically, the inner elastomeric body 347 is coupled to an outer lateral stop mounting bracket 349a coupled to the outer rim 333. The inner hinge brackets 346a, 346b are coupled by hinge pins 348. In some embodiments, the outer lateral stop mounting bracket 349a may not be used, such as, for example, the inner elastomeric body 347 may be directly coupled to the outer ring 340, such as, for example, by hinge pins 348. The hinge bracket 346b is coupled to the inner rim 331 via an inner transverse stop mounting bracket 349b, which is coupled to the inner rim via a hinge pin 348 coupled to the inner transverse stop mounting bracket. In some embodiments, the hinge bracket 346b may be coupled to the inner rim 331 without the inner transverse stop mounting bracket 349b, for example, directly coupled to the inner rim via the hinge pin 348.

[0135] The wheel assembly 330 also includes an outer lateral stop 345 coupled between the outer side of the outer rim 333 and the outer side of the inner rim 331. More specifically, the outer lateral stop 345 is illustratively in the form of a hinge retainer or a scissor hinge similar to the inner lateral stop 344. That is, each outer lateral stop 345 includes an outer hinge bracket 346a, 346b and an outer elastomeric body 347, such as a polyurethane body, carried by the hinge bracket adjacent to the outer rim 333. More specifically, the outer elastomeric body 347 is coupled to an outer lateral stop mounting bracket 349a coupled to the outer rim 333. The hinge brackets 346a, 346b are coupled by a hinge pin 348. In some embodiments, the outer lateral stop mounting bracket 349a may not be used, such as, for example, the outer elastomeric body 347 may be directly coupled to the outer ring 340, such as, for example, by a hinge pin 348. The hinge bracket 346b is coupled to the inner rim 331 via an inner transverse stop mounting bracket 349b, which is coupled to the inner rim via a hinge pin 348 coupled to the inner transverse stop mounting bracket. In some embodiments, the hinge bracket 346b may be coupled to the inner rim 331 without the inner transverse stop mounting bracket 349b, for example, directly coupled to the inner rim via the hinge pin 348.

[0136] Those skilled in the art will appreciate that the inner lateral stop 344 and the outer lateral stop 345 limit the relative movement of the outer rim 333 (and thus the outer ring 340) and the inner rim 331 similarly to the lateral stops described with respect to the above embodiments. In other words, for example, turning of the vehicle may cause the outer ring 340 to move laterally relative to the inner rim 331. The inner lateral stop 344 and the outer lateral stop 345 may limit the amount of lateral movement of the outer ring 340 relative to the inner rim 331, thereby maintaining the structural integrity of the wheel assembly 330. Of course, the inner lateral stop 344 and the outer lateral stop 345 may include other and / or additional components or elements that cooperate to limit the relative lateral movement of the outer ring 340 and the inner rim 331.

[0137] The other elements shown (e.g., the fastener receiving passage 324 in the inwardly extending flange ring 325, the tread assembly 370, and the clamping device 373 including the inner clamping member 374 and the fastener 379a) are similar to the corresponding elements described in relation to the above-mentioned embodiments. Therefore, these elements related to the present embodiment do not require further discussion.

[0138] One aspect of the method relates to a method of manufacturing a wheel assembly 330 to be coupled to a wheel hub of a vehicle. The method includes operably coupling a plurality of gas springs 350 between an inner rim 331 of a wheel hub to be coupled to a vehicle and an outer rim 333 surrounding the wheel hub to provide a gas suspension for relative movement between the inner rim and the outer rim. The method may also include coupling an outer ring 340 to the outer rim 333, the outer ring and adjacent inner portions of the inner rim defining a closable gap 341 to define a mechanical stop to limit relative movement of the inner rim and the outer rim.

[0139] Now refer to Figure 34 to Figure 35 In another embodiment of the wheel assembly 330', the outer ring 340a' is coupled to the outer rim 333', and the inner ring 340b' is coupled to the inner rim 331'. The adjacent portions of the inner ring 340b' and the outer ring 340a' define a closable gap 341' to define a mechanical stop to limit the relative movement of the inner rim 331' and the outer rim 333'. Similar to the above embodiment, the outer rim 333' can have a diameter of at least 3.5 feet.

[0140] The outer ring 340a' has an outer ring body 363a' and an outer ring edge cap 364a' carried by the inner edge of the outer ring body. The inner ring 340b' also includes an inner ring body 363b' and an inner ring edge cap 364b' carried by the outer edge of the inner ring body. The inner ring edge cap 364a' and the outer ring edge cap 364b' provide a mechanical stop with increased surface area to limit the relative movement of the inner rim 331' and the outer rim 333'.

[0141] Similar to the above-described embodiments, the outer ring 340a' also includes a lightening opening 343a' therein. The inner ring 340b' also includes a lightening opening 343b' therein. The lightening openings 343a', 343b' each illustratively have a generally rounded or circular shape. The lightening openings 343a', 343b' may, for example, have another shape, such as an elliptical, hexagonal, and / or a profile for reducing stress.

[0142] The gas springs 350' are operably coupled between the inner rim 331' and the outer rim 333'. Each gas spring 350' may be, for example, a double-acting gas spring and include a double-acting cylinder 351' and an associated piston 352'. Of course, in some embodiments, each gas spring 350' may be a single-acting gas spring. More than one type of gas spring 350' may be used. The gas spring 350' may be, for example, an air spring and / or a nitrogen spring. The gas spring 350' may also include other gases.

[0143] Exemplarily, the gas springs 350' are arranged in pairs on opposite sides of the outer ring 340a'. More specifically, the gas springs 350' diverge outwardly from the inner rim 331' to the outer rim 333'. A corresponding attachment bracket 353' for each gas spring 350' is coupled to the inner ring 340b', more specifically, to the inner ring body 363b'. Each attachment bracket 353' can include a generally U-shaped or V-shaped base bracket that receives an end of a piston 352' therein (e.g., between the arms of the U-shaped or V-shaped bracket). Fasteners fasten the end of the piston 352' of the gas spring 350' to the base bracket. Similar attachment brackets 353' are coupled to the outer rim 333' adjacent to the inner and outer side surfaces. Thus, the gas spring 350' is pivotably coupled between the inner rim 331' and the outer rim 333'.

[0144] Similar to the above-described embodiments, as will be appreciated by those skilled in the art, the gas spring 350' provides a gas suspension for relative movement between the inner rim 331' and the outer rim 333'. The gas spring 350' has an operating stroke that allows the outer ring 340a' to define a mechanical stop. In other words, the gas spring 350' keeps the outer rim 333' spaced apart from the inner rim 331'. However, if the pressure on any of the gas springs 350' causes the gas spring to reach its limit under load or the gas spring fails, the outer ring 340a' can act as a mechanical stop to limit the relative movement of the inner rim 331' and the outer rim 333'. In other words, the outer rim 340a' and the gas spring 350' can be considered to provide a run-flat capability. Since the gas spring 350' is similar to the gas spring described with respect to the above embodiments, further details of the gas spring do not need to be described.

[0145] In addition, refer to Fig.37 , the wheel assembly 330' also includes an inner lateral stop 344' carried between the inner side of the outer rim 333' and the inner side of the inner rim 331'. More specifically, the inner lateral stop 344' is illustratively in the form of a hinge retainer or a scissor hinge. Each inner lateral stop 344' includes an inner hinge bracket 346a', 346b' and an inner elastomeric body 347', such as a polyurethane body, carried by the hinge bracket adjacent to the inner side of the outer ring 340a'. The inner elastomeric body 347' is connected to the wall portion of the outer ring 340a' by a hinge pin 348'. The hinge brackets 346a', 346b' are connected together by the hinge pin 348'. The hinge bracket 346b' is connected to the wall portion of the inner ring 340b' by the hinge pin 348'.

[0146] The wheel assembly 330' also includes an outer lateral stop 345' carried between the outer side of the outer rim 333' and the outer side of the inner rim 331'. More specifically, the outer lateral stop 345' is illustratively in the form of a hinge retainer or a scissor hinge. Each outer lateral stop 345' includes an outer hinge bracket 346a', 346b' and an outer elastomeric body 347', such as a polyurethane body, carried by the hinge bracket adjacent to the outer side of the outer ring 340a'. The outer elastomeric body 347' is connected to the wall portion of the outer ring 340a' opposite to the corresponding portion of the inner lateral stop 344' by a hinge pin 348', and the hinge pin 348' can be shared with the hinge pin of the inner lateral stop. The hinge brackets 346a', 346b' are connected by the hinge pin 348'. Hinge bracket 346b' is coupled to a wall portion of inner ring 340b' opposite a corresponding portion of inner lateral stop 344' by hinge pin 348', which can be shared with the hinge pin of the inner lateral stop. As will be appreciated by those skilled in the art, inner lateral stop 344' is similar in structure to outer lateral stop 345', but is located opposite (i.e., on the inner side) the outer lateral stop.

[0147] Those skilled in the art will appreciate that the inner lateral stop 344' and the outer lateral stop 345' limit the relative movement of the outer ring 340a' and the inner ring 340b'. In other words, for example, turning of the vehicle may cause the outer ring 340a' to move laterally relative to the inner ring 340b'. The inner lateral stop 344' and the outer lateral stop 345' may limit the amount of lateral movement of the outer ring 340a' relative to the inner ring 340b', thereby maintaining the structural integrity of the wheel assembly 330'. Of course, the inner lateral stop 344' and the outer lateral stop 345' may include other and / or additional components or elements that cooperate to limit the relative lateral movement of the outer ring 340a' and the inner rim 331'.

[0148] The other elements shown (eg, tread assembly 370' and clamping device 373' including inner clamping member 374' and fastener 379a') are similar to corresponding elements described with respect to the above-described embodiments. Therefore, these elements need not be discussed further with respect to the present embodiment.

[0149] One aspect of the method relates to a method of manufacturing a wheel assembly 330' to be coupled to a wheel hub of a vehicle. The method includes operably coupling a plurality of gas springs 350' between an inner rim 331' of a wheel hub to be coupled to a vehicle and an outer rim 333' surrounding the wheel hub to provide a gas suspension for relative movement between the inner rim and the outer rim. The method also includes coupling an outer ring 340a' to the outer rim 333' and coupling an inner ring 340b' to the inner rim 331', adjacent inner portions of the inner and outer rings defining a closable gap 341' to define a mechanical stop to limit relative movement of the inner rim and the outer rim.

[0150] Now refer to Figures 38 to 40 In another embodiment, the wheel assembly 430 is segmented to facilitate transportation and allow maintenance of the individual segments. More specifically, the wheel assembly 430 includes a segmented circular inner rim 431 to be coupled to the wheel hub. The arcuate inner rim assemblies 431a, 431b, 431c are removably coupled together to define the circular inner rim 431. Although three arcuate inner rim assemblies 431a, 431b, 431c are illustrated, it will be understood by those skilled in the art that there may be any number of arcuate inner rim assemblies, for example, 2 arcuate inner rim assemblies to 4 arcuate inner rim assemblies.

[0151] The mounting ring 490 extends inwardly from the circular inner rim 431. The mounting ring 490 illustratively includes an inner opening 491 and an outer opening 492 therein. The outer opening 491 is spaced apart along the outer circumference of the mounting ring 490 relative to the inner opening 492, which is spaced apart along the inner circumference of the mounting ring. Illustratively, the inner opening 492 is smaller in size (i.e., diameter) relative to the outer opening 491. The mounting ring 490 including the outer opening 491 and the inner opening 492 can advantageously define what can be conceptually viewed as a universal mount that can be adapted for wheels of different sizes (e.g., diameters), for example, on trucks and loaders of various sizes. As will be appreciated by those skilled in the art, the mounting ring 490 can clear the wheel hub of the vehicle by an amount of radial displacement, so consideration and / or inspection of a fluid reservoir (e.g., brake fluid) can be facilitated.

[0152] Each arcuate inner rim assembly 431a, 431b, 431c includes an arcuate inner rim segment 432b and an arcuate inner ring segment 440b extending radially outward from the arcuate inner rim segment, similar to the above Figure 34 to Figure 36 Each inner ring segment 440b includes an inner ring body 463b and an inner ring edge cap 464b carried by the outer edge of the inner ring body. Each arcuate inner ring segment 440b also includes a lightening opening 443b therein.

[0153] Each segmented or arcuate inner rim assembly 431a, 431b, 431c has end flanges 418a, 418b at opposite ends. More specifically, a respective inner flange 418a, 418b is located at each end of the arcuate inner rim segment 432b and the arcuate inner ring segment 440b for coupling adjacent arcuate inner rim assemblies 431a, 431b, 431c in an end-to-end relationship. Each inner flange 418a, 418b has an opening or inner flange fastener receiving passage therein to receive an inner flange fastener 419 therethrough when the opening or inner flange fastener receiving passage is aligned with an adjacent end flange.

[0154] The wheel assembly 430 also includes an outer rim 433 having a circular shape. Similar to the circular inner rim 431, the circular outer rim 433 is segmented or defined by arcuate outer rim components 433a, 433b, 433c that are coupled together. Although three arcuate outer rim components 433a, 433b, 433c are illustrated, it will be understood by those skilled in the art that there may be any number of arcuate outer rim components, for example, 2 arcuate outer rim components to 4 arcuate outer rim components, and the number of arcuate outer rim components does not need to match the number of arcuate inner rim components 431a, 431b, 431c. In addition, in other embodiments, the joints in the arcuate outer rim components 433a, 433b, 433c do not need to be aligned with the corresponding joints in the arcuate inner rim components 431a, 431b, 431c.

[0155] The number of arcuate inner rim assemblies 431a, 431b, 431c and arcuate outer rim assemblies 433a, 433b, 433c can depend on the overall size of wheel assembly 430. Other considerations for the size of each segment or arcuate inner rim assembly and arcuate outer rim assembly can include transportation constraints (e.g., weight, size, cost, etc.). Of course, the number of segment or arcuate inner rim assemblies 431a, 431b, 431c and arcuate outer rim assemblies 433a, 433b, 433c can be based on other and / or additional factors. Arcuate inner rim assemblies 431a, 431b, 431c and arcuate outer rim assemblies 433a, 433b, 433c can be connected or assembled on site.

[0156] Each arcuate outer rim assembly 433a, 433b, 433c (which is similar to each arcuate inner rim assembly 431a, 431b, 431c and similar to the above with respect to Figure 34 to Figure 36 The embodiment described in the embodiment includes an arcuate outer rim segment 432a and an arcuate outer ring segment 440a extending radially inward from the arcuate outer rim segment. Similar to the above embodiment, each arcuate outer ring segment 440a has an outer ring body 463a and an outer ring edge cap 464a carried by the inner edge of the outer ring body. Also similar to the above embodiment, each arcuate outer ring segment 440a also includes a weight reduction opening 443a therein.

[0157] Each arcuate outer rim assembly 433a, 433b, 433c also has end flanges 415a, 415b at opposite ends. More specifically, a respective outer flange 415a, 415b is located at each end of the arcuate outer rim segment 432a and the arcuate outer ring segment 440a for coupling adjacent arcuate outer rim assemblies 433a, 433b, 433c in an end-to-end relationship. Each outer flange 415a, 415b has an opening or outer flange fastener receiving passage 417 therein to receive an outer flange fastener 416 therethrough when the opening or outer flange fastener receiving passage 417 is aligned with an adjacent outer flange.

[0158] Similar to the above Figure 34 to Figure 36 In the described embodiment, the arcuate outer ring segment 440a and the arcuate inner ring segment 440b define a closable gap 441 therebetween to define a mechanical stop. Thus, relative movement between the arcuate outer ring segment 440a and the arcuate inner ring segment 440b is limited.

[0159] In addition, although about Figures 38 to 40 Not specifically shown or described, wheel assembly 430 includes a gas spring (shown in other figures) operably coupled between circular inner rim 431 and circular outer rim 433 to provide gas suspension for relative movement therebetween. The gas spring may radiate outwardly from arcuate inner rim segment 432a to arcuate outer rim segment 432b. For example, Fig.32 and Fig.34 as well as Figure 41 to Figure 44 An exemplary arrangement of a gas spring is shown in Wheel assembly 430 may also include an attachment bracket, a cover, a cover ring, a bellows, and / or any other element described herein.

[0160] One aspect of the method relates to a method of assembling a wheel assembly 430 to be coupled to a wheel hub of a vehicle. The method includes coupling a plurality of arcuate inner rim assemblies 431a, 431b, 431c together to define a circular inner rim 431 to be coupled to the wheel hub of the vehicle. Each arcuate inner rim assembly 431a, 431b, 431c includes an arcuate inner rim segment 432b and an arcuate inner ring segment 440b extending radially outward from the arcuate inner rim segment. The method also includes coupling a plurality of arcuate outer rim assemblies 433a, 433b, 433c together to define a circular outer rim 433. Each arcuate outer rim assembly 433a, 433b, 433c includes an arcuate outer rim segment 432a and an arcuate outer ring segment 440a extending radially inward from the arcuate outer rim segment. The method also includes operably coupling a plurality of gas springs between the circular inner rim 431 and the circular outer rim 433 to provide a gas suspension for relative movement therebetween.

[0161] Now refer to Figures 41 to 49 In another embodiment, a segmented wheel assembly 530 (similar to the above with respect to Figures 38 to 40 The embodiment described includes an outer rim 533 including an outer ring 540a, which is segmented into three segments 533a, 533b, 533c, each of which includes end flanges 515a, 515b at opposite ends. Each end flange 515a, 515b has an opening therein to receive a fastener 516 therethrough when the opening is aligned with an adjacent end flange.

[0162] The wheel assembly 530 also includes a segmented inner rim 531, which is segmented into three inner rim segments 531a, 531b, 531c. Each inner rim segment 531a, 531b, 531c has end flanges 518a, 518b at opposite ends. Each end flange 518a, 518b has an opening therein to receive a fastener 519 therethrough when the opening is aligned with an adjacent end flange. The inner rim 531 also includes an inwardly extending flange 525 having a fastener receiving passage 524 therein for coupling to a wheel hub of a vehicle. In some embodiments, the above-mentioned universal mounting ring including an inner opening and an outer opening can be used for or coupled to the inner rim 531.

[0163] The outer ring 540a is coupled to the outer rim 533, and the inner ring 540b is coupled to the inner rim 531. Adjacent portions of the inner ring 540b and the outer ring 540a define a closable gap 541 to define a mechanical stop to limit relative movement of the inner rim 531 and the outer rim 533.

[0164] The outer ring 540a has an outer ring body 563a and an outer ring edge cap 564a carried by the inner edge of the outer ring body. The inner ring 540b also includes an inner ring body 563b and an inner ring edge cap 564b carried by the outer edge of the inner ring body. Also similar to the above embodiment, the outer ring 540a also includes a weight-reducing opening 543a therein. The inner ring 540b also includes a weight-reducing opening 543b therein.

[0165] The gas springs 550 are operably coupled between the inner rim 531 and the outer rim 533. Each gas spring 550 can be, for example, a double-acting gas spring and include a double-acting cylinder 551 and an associated piston 552. Of course, in some embodiments, each gas spring 550 can be a single-acting gas spring. More than one type of gas spring 550 can be used. The gas spring 550 can be, for example, an air spring and / or a nitrogen spring. The gas spring 550 can also include other gases. The gas spring 550 is similar to the gas spring described above. Figure 34 to Figure 36 The described embodiment is arranged, and more specifically, the gas springs 550 are arranged in pairs on opposite sides of the outer ring 540a. Exemplarily, the gas springs 550 diverge outwardly from the inner rim 531 to the outer rim 533. A corresponding attachment bracket 553 for each gas spring 550 is coupled to the inner rim 531 and the outer rim 533. Accordingly, the gas spring 550 is pivotably coupled between the inner rim 531 and the outer rim 533. Similar to the above-described embodiment, as will be understood by those skilled in the art, the gas spring 550 provides a gas suspension for relative movement between the inner rim 531 and the outer rim 533.

[0166] The wheel assembly 530 also includes an inner lateral stop 544, which is carried between the inner side of the outer rim 533 and the inner side of the inner rim 531 (and more specifically, the inner side of the inner ring 540b). The inner lateral stop 544 is illustratively in the form of a hinge retainer or a scissor hinge. Each inner lateral stop 544 includes an inner hinge bracket 546a, 546b. The hinge brackets 546a, 546b are coupled together by a hinge pin 548. The hinge bracket 546b is coupled to the wall portion of the inner ring 540b by the hinge pin 548.

[0167] Hinge bracket 546a is coupled to a transverse stop mount 549 carried by the inner surface of outer rim 533. More specifically, transverse stop mount 549 is coupled to outer ring 540a and outer rim 533 by flange 562 which receives fastener 579 therethrough.

[0168] Each lateral stop mount 549 includes an anvil body 561 that is embedded or carried within an elastomeric body 547, and more specifically, a cast polyurethane body, such as Duro 55 polyurethane. The elastomeric body 547 may be formed (e.g., extruded or bonded) in two segments or pieces and may have an opening 567 in its bottom portion, as shown ( Figure 47 to Figure 49 ) (e.g., a protruding hole). In some embodiments, the elastomeric body 547 may not include the opening 567 or include another number of openings. The elastomeric body 547 may have a radius that is slightly smaller than the adjacent or matching inner surface of the outer rim 533 so that the bottom portion of the elastomeric body can protrude downward. As will be appreciated by those skilled in the art, the elastomeric body 547 increases flexibility while maintaining strength. Additional details of the exemplary elastomeric body 547 can be found in U.S. Patent Nos. 4,727,695 to Kemeny, 5,054,251 to Kemeny, 5,215,382 to Kemeny, and 5,242,147 to Kemeny, all of which are hereby incorporated by reference in their entirety.

[0169] The anvil body 561 exemplarily has an anvil shape having an enlarged base or dovetail adjacent to the outer rim 533. The anvil body 561 has an upper opening 566a to receive a hinge pin 548 passing therethrough, the hinge pin 548 being coupled to the hinge bracket 546b. The upper opening 566a coupled to the hinge pin 548 is exposed from the elastomeric body 547. The anvil body 561 has two additional openings 566b vertically aligned with the hinge pin openings. The additional openings 566b are particularly advantageous as weight-reducing openings. There may be any number of additional openings 566b. The additional openings 566b are embedded or carried in the elastomeric body 547 so as not to be exposed. As will be appreciated by those skilled in the art, the anvil body 561 may be subjected only to shear forces and moments. Tension and compression associated with the anvil body 561 may be considered negligible.

[0170] Each lateral stop mounting member 549 also includes a stop anchor housing 568 surrounding or above the elastomeric body 547. Similar to the elastomeric body 547, the anchor housing 568 can be illustratively two-piece, with an opening in the top of the anchor housing 568 when the two pieces are coupled together to allow the anvil body 561 to extend, and more specifically, to allow the upper opening 566a of the anvil body to be exposed for coupling to the hinge bracket 546b. The above-mentioned flange 562 extends laterally from the anchor housing 568 on the inner side of the outer rim 533 and the corresponding side of the outer ring 540a.

[0171] The wheel assembly 530 also includes an outboard lateral stop 545 carried between the outboard side of the outer rim 533 and the outboard side of the inner rim 531 (and more specifically, the outboard side of the inner ring 540b). The outboard lateral stop 545 is laterally aligned with the inboard lateral stop 544 on the opposite side of the outer ring 540a. The outboard lateral stop 545 is illustratively in the form of a hinge retainer or a scissor hinge. More specifically, the outboard lateral stop 545 is similar in structure to the inboard lateral stop 544 and therefore does not require further description herein.

[0172] Wheel assembly 530 also includes a tread assembly 570 carried by outer rim 533. Each tread assembly 570 is in the form of an arcuate metal plate coupled to the outer circumference of outer rim 533 by fasteners 571. Each tread assembly 570 has outwardly folded ends that define traction features. Those skilled in the art will appreciate that, given the arcuate shape of tread assembly 570, several tread assemblies are coupled in end-to-end relationship around outer rim 533. Other types and / or configurations of tread assemblies 570 may be used.

[0173] Other elements described herein with respect to other embodiments but not specifically shown or described can be used with the elements of this embodiment. These elements similar to those described above do not need to be further described with respect to this embodiment. In addition, one or more method aspects can include a method of manufacturing wheel assembly 530.

[0174] Now refer to Figure 50 to Figure 53 In another embodiment, the inner rim 531' includes a mounting ring 590' as described above, which extends inwardly from the inner rim 531' and includes an inner opening 591' and an outer opening 592' therein. In other words, the wheel assembly 530' includes a universal mount that can be adapted, for example, for wheels of different sizes (e.g., diameters) on trucks and loaders of various sizes.

[0175] Additionally, each tread component 570' includes a weight-reducing opening 578' therein. Figure 41 to Figure 44 The tread assembly described herein, tread assembly 570' is carried by outer rim 533'. Each tread assembly 570' is in the form of an arcuate metal plate and includes downwardly folded side portions 577' for coupling to the inner and outer sides of outer rim 533' via fasteners 571'. As opposed to fasteners that couple through the outer circumference of the outer rim, downwardly folded side portions 577' secure tread assembly 570'. Because this embodiment of tread assembly 570' includes lightening openings 578' therein, fasteners that pass through the outer circumference of outer rim 533' would be undesirable. Moreover, similar to the above description of the embodiment of tread assembly 570', the outer circumference of outer rim 533' is not necessarily connected to the outer rim 533'. Figure 41 to Figure 44Tread components 570' are depicted, each having outwardly folded ends that define traction features.

[0176] Wheel assembly 530' also includes a rigid inner cover ring 593' coupled to the inner side of outer rim 533', for example, by fasteners 507a'. Rigid inner cover ring 593' is illustratively segmented, similar to inner ring 540a' and outer ring 540b'. In some embodiments, rigid inner cover ring 593' may not be segmented. Rigid inner cover ring 593' extends radially inward toward inner rim 531'. More specifically, rigid inner cover ring 593' defines a radially and axially extending inner gap with inner rim 531'.

[0177] A flexible inner seal 509a', for example in the form of an inner bellows seal, is coupled between the rigid inner cover ring 593' and the inner rim 531', for example, by corresponding fasteners 508a' to couple to the inner rim. More specifically, the rigid inner cover ring 593' has a relatively thin flange end to be slidably received in a channel (e.g., a U-shape that matches the flange end). The inner bellows seal 509a' also includes another channel for coupling (e.g., by slidably receiving the flange of the inner rim 531') to the inner rim. The inner bellows seal 509a' is also illustratively segmented, similar to the rigid inner cover rim 593' and the inner rim 531' and the outer rim 533'.

[0178] The flexible inner seal 509a' closes the radially and axially extending inner gap and allows the inner rim 531' and the outer rim 533' to move relative to each other. Exemplarily, the inner bellows seal 509a' has a W-shaped cross-section. For example, the flexible inner seal 509a' can be a different kind of flexible seal and can have a cross-section of different shapes. The flexible inner seal 509a' can include rubber and / or elastomeric materials. The flexible inner seal 509a' can include other and / or additional materials.

[0179] Wheel assembly 530' also includes a rigid outer cover ring 594' coupled to the outer side of outer rim 533', for example, by fasteners. Rigid outer cover ring 594' is schematically segmented, similar to inner ring 540a' and outer ring 540b'. In some embodiments, rigid outer cover ring 594' may not be segmented. Rigid outer cover ring 594' extends radially inward toward inner rim 531'. More specifically, rigid outer cover ring 594' defines a radially and axially extending outer gap with inner rim 531'.

[0180] A flexible outer seal 509b', for example in the form of an outer bellows seal, is coupled between the rigid outer cover ring 594' and the inner rim 531', for example by corresponding flanges as described above with respect to the flexible outer seal. Similar to the inner flexible seal 509a', the outer flexible inner seal 509b' closes the radially and axially extending outer gap and allows the inner rim 531' and the outer rim 533' to move relative to each other. The outer bellows seal 509b' similarly has a W-shaped cross-section. For example, the flexible outer seal 509b' can be a different kind of flexible seal and can have a cross-section of different shapes. The outer bellows seal 509b' is also exemplarily segmented, similar to the rigid inner cover ring 593' and the inner rim 531' and the outer rim 533'.

[0181] Elements shown but not specifically described, such as the gas spring 550' and the lateral stops 544', 545', are similar to those described above with reference to Figures 41 to 49 Therefore, no further description of these elements is required. In addition, one or more method aspects can include a method of manufacturing a wheel assembly 530'.

[0182] Now refer to Figure 52 to Figure 55 In another embodiment of the segmented wheel assembly 630, the lateral stop mounts 644, 645 each include a gas spring 647 and do not include an elastomeric body, as will be described in further detail below. The inner lateral stop 644 is carried between the inner side of the outer rim 633 and the inner side of the inner rim 631 (and more specifically, the inner side of the inner ring 640b) by the gas spring 647.

[0183] Each gas spring 647 is coupled to the inner hinge bracket 646b by a hinge pin 648 to allow pivoting about the inner hinge bracket 646b when moving inwardly or outwardly relative to each other. The gas spring 647 limits lateral movement similarly to any lateral stop described herein. The gas springs 647 each include a cylinder 667 and an associated piston 668. For example, the gas spring 647 can be a short-stroke cylinder. The gas spring 647 is operated by the movement of the inner hinge brackets 646a, 646b. The gas springs 647 each include a flange 662 extending outwardly (e.g., radially) from the cylinder 667, and the flange 662 is coupled to the inner ring 640b by a fastener 679, and more specifically, to the inner ring body 663b.

[0184] The hinge bracket 646a is coupled to a transverse stop mount 649 carried by the inner surface of the outer rim 633. Figures 41 to 49In the depicted embodiment, each lateral stop mounting member 649 includes an anvil body 661. In contrast to other embodiments, the anvil body is not embedded or carried in an elastomeric body.

[0185] The anvil body 661 illustratively has an anvil shape with an enlarged base or dovetail adjacent to the outer rim 633. The anvil body 661 has an upper opening to receive a hinge pin 648 therethrough, which is coupled to the hinge bracket 646a. The anvil body 661 has an additional opening 666 vertically aligned with the hinge pin opening. The additional opening 666 is particularly advantageous as a weight-reducing opening. There may be any number of additional openings 666.

[0186] The wheel assembly 630 also includes an outboard lateral stop 645 carried between the outboard side of the outer rim 633 and the outboard side of the inner rim 631 (and more specifically, the outboard side of the inner ring 640b). The outboard lateral stop 645 is laterally aligned with the inboard lateral stop 644 on the opposite side of the outer ring 640a. The outboard lateral stop 645 is illustratively in the form of a hinge retainer or a scissor hinge. More specifically, the outboard lateral stop 645 is similar in structure to the inboard lateral stop 644 and therefore does not require further description herein.

[0187] Other elements described herein with respect to other embodiments but not specifically shown or described may be used with elements of this embodiment. The following elements are similar to those described above: for example, a gas spring 650 including a corresponding cylinder 651 and an associated piston 652 and an attachment bracket 653; a flange 625 extending inwardly from the inner rim 631 and having a fastener receiving passage 624 therein for coupling to a wheel hub of a vehicle; end flanges 615a, 615b, 618a, 618b and fasteners 616; an inner ring body 663a and an outer ring body 663b; an inner ring edge cap 664a and an outer ring edge cap 664b; and openings 643a, 643b, and need not be further described with respect to this embodiment. In addition, one or more method aspects may include a method of manufacturing a wheel assembly 630.

[0188] Now refer to Figure 56 to Figure 57 In another embodiment, the wheel assembly 730 may include an inner sidewall cover assembly 701a and an outer sidewall cover assembly 701b. The inner sidewall cover assembly 701a and the outer sidewall cover assembly 701b each include an inner sidewall cover 793 coupled to the inner rim 731. Each inner sidewall cover 793 extends radially outward toward the outer rim 733. Exemplarily, each inner sidewall cover 793 includes an inner sidewall panel 796a.

[0189] Each of the inner side wall cover assembly 701a and the outer side wall cover assembly 701b further includes an outer side wall cover 794, which is coupled to the outer rim 733, for example, using fasteners 797. A rubber gasket or seal may be located between the outer side wall cover 794 and adjacent portions of the outer rim 733. Each outer side wall cover 794 extends radially inwardly toward the inner rim 731. Each outer side wall cover 794 is also in a sliding overlapping relationship with the inner side wall cover 793, thereby allowing relative movement between the inner side wall cover and the outer side wall cover. Exemplarily, the outer side wall cover 794 overlaps (i.e., overlaps axially outwardly) the inner side wall cover 793 for the outer side wall cover assembly 701b, and the inner side wall cover overlaps (i.e., overlaps axially outwardly) the outer side wall cover for the inner side wall cover assembly.

[0190] Illustratively, each outer sidewall cover 794 includes an outer sidewall panel 796b and an outer wiper device 798 extending from the outer sidewall panel toward the inner sidewall cover 793 and in sliding contact with the inner sidewall cover 793. As will be appreciated by those skilled in the art, the outer sidewall panel 796b may include, for example, steel and / or aluminum, which may depend on the application or environment.

[0191] The outer wiper arrangement 798 is adjacent to the radially inward edge of the outer sidewall panel 796b and extends axially inwardly. The outer wiper arrangement 798 may include a spaced outer sidewall lip 799b adjacent to the radially inward edge of the outer sidewall panel 796b and extending axially inwardly to define a channel therebetween.

[0192] For example, the wiper blade 702 comprising an elastic material can be carried in the channel. The wiper blade 702 can include rubber, for example, a foam rubber that can be a foam backing. Of course, other and / or additional materials can be used, for example, polytetrafluoroethylene (PTFE), polyethylene, such as ultra-high molecular weight polyethylene. Although relative movement occurs between the outer sidewall cover 794 and the inner sidewall cover 793, the interface between the outer wiper device 798 and the inner sidewall panel 796a can be waterproof and / or dustproof.

[0193] Now refer to Fig.58 In another embodiment, for both the inner side wall cover assembly 701a' and the outer side wall cover assemblies 701a', 701b', the outer side wall cover 794' overlaps (i.e., overlaps axially outwardly) the inner side wall cover 793'. Thus, the outer wiper device 798' includes an outer side wall lip 799b' adjacent to the radially inward edge of the outer side wall panel 796b' and extending axially outwardly to define a channel therebetween. The elements illustrated but not specifically described are similar to those described above.

[0194] Briefly refer to Fig.59 In another embodiment, each inner wall cover 793" may include an inner wall panel 796a" and an inner wiper device 798", wherein the inner wiper device 798" extends from the inner wall panel toward the outer wall cover 794" and is in sliding contact with the outer wall cover 794". As will be appreciated by those skilled in the art, similar to the inner wall panel 796a", the outer wall panel 796b" may include, for example, steel and / or aluminum, which may depend on the application or environment.

[0195] The inner wiper device 798" is adjacent to the radially outward edge of the inner wall panel 796a" and extends axially outward. The inner wiper device 798" may include a spaced-apart inner wall lip 799a", which is adjacent to the radially outward edge of the inner wall panel 796a" and extends axially outward to define a channel therebetween.

[0196] For example, a wiper blade 702" comprising an elastomeric material may be carried in the channel. The wiper blade 702" may comprise rubber, for example, foam rubber that may be foam backed. Of course, other and / or additional materials may be used, for example, polytetrafluoroethylene (PTFE), polyethylene, such as ultra high molecular weight polyethylene. The elements illustrated but not specifically described are similar to those described above.

[0197] Now refer to Fig.60 In another embodiment, both the inner side wall cover 793'" and the outer side wall cover 794'" may include respective inner wiper arrangements 798a'" and outer wiper arrangements 798b'" as described above. Elements illustrated but not specifically described are similar to those described above.

[0198] Although an exemplary outer wiper device 798b"' has been described that includes lips 799a"', 799b"', those skilled in the art will understand that in some embodiments, the lip may not be included. For example, the outer side wall panel 796b"' may have a groove or channel formed therein, and may carry a wiper device 798b"' that may include an elastomeric material wiper scraper 702"' within the groove or channel. In addition, although embodiments have been described herein with respect to an inner side wall cover assembly 701a and an outer side wall cover assembly 701b, those skilled in the art will understand that the inner side wall cover assembly and the outer side wall cover assembly may each have different arrangements relative to the inner side wall cover 793"' and the outer side wall cover 794"' and the wiper devices 798a"', 798b"'.

[0199] Similar to the above-described embodiments, the wheel assembly 730 includes an outer ring 740 coupled to the outer rim 733, the outer ring 740 extending radially inward from the outer rim. For example, as described above, the outer ring 740 can define a closable gap with an adjacent portion of the inner rim 731 to define a mechanical stop to limit relative movement of the inner rim and the outer rim. The gas springs 750 diverge outwardly from the inner rim 731 to the outer rim 733 and are arranged in pairs on opposite sides of the outer ring 740, so that the gas springs 750 can have an operating stroke that allows the outer ring to define a mechanical stop. The gas springs 750 are coupled to the inner rim 731 and the outer rim 733 by corresponding attachment brackets 753.

[0200] The wheel assembly 730 also includes an outboard lateral stop 745, illustratively in the form of a scissor hinge or hinge retainer, which is carried between the outside of the outer rim 733 and the outside of the inner rim 731 (and more specifically, the outside of the outer ring 740). The outboard lateral stop 745 is similar in structure to those described above and does not need to be further described here. In addition, the wheel assembly 730 may also include an inboard lateral stop, which is also similar to the embodiments of the outboard lateral stop and the inboard lateral stop described herein.

[0201] The other elements shown, such as the fastener receiving passages 724 in the inwardly extending flange ring 725, the tread assembly 770 and the clamping device 773, are similar to the corresponding elements described with respect to the above embodiments. Therefore, these elements related to the present embodiment do not require further discussion.

[0202] Those skilled in the art will appreciate that in some embodiments, the wheel assembly 730 may additionally or alternatively include an inner ring coupled to the inner rim 731, the inner ring extending radially outward from the inner rim to define a closable gap with an adjacent portion of the outer ring 740 to define a mechanical stop to limit the relative movement of the inner rim and the outer rim. In this case, the gas spring 750 may thus have an operating stroke that allows the outer ring 740 and the inner ring to define the mechanical stop.

[0203] One aspect of the method relates to a method of assembling a wheel assembly 730 to be coupled to a wheel hub of a vehicle. The method includes coupling a plurality of gas springs 750 between an inner rim 731 and an outer rim 733 to be coupled to the wheel hub to provide a gas suspension that allows relative movement between the inner rim and the outer rim. The method also includes coupling an inner sidewall cover 793 of a sidewall cover assembly 701a to the inner rim 731 and extending the inner sidewall cover 793 radially outward toward the outer rim 733, and coupling an outer sidewall cover 794 of a sidewall cover assembly 701b to the outer rim and extending the outer sidewall cover 794 radially inward toward the inner rim and the outer sidewall cover 794 is in a sliding overlapping relationship with the inner sidewall cover, thereby allowing relative movement between the inner sidewall cover and the outer sidewall cover.

[0204] Although several embodiments have been described herein, those skilled in the art will appreciate that any one or more elements from any one or more embodiments may be used in combination with any one or more elements from any one or more other embodiments. In addition, although reference is made herein to internal and external, those skilled in the art will appreciate that in many embodiments, elements described with respect to internal may be used as external elements, and vice versa; and / or those elements described as internal may be used with elements described as external, and vice versa.

[0205] Many modifications and other embodiments of the present invention will come to mind to one skilled in the art having the benefit of the teachings presented in the foregoing descriptions and the associated drawings.Therefore, it will be understood that the present invention is not limited to the particular embodiments disclosed.

Claims

1. A wheel assembly to be coupled to a wheel hub of a vehicle, the wheel assembly comprising: an inner rim of the wheel hub to be coupled to the vehicle; an outer rim surrounding the inner rim; an outer ring coupled to the outer rim and extending radially inwardly from the outer rim to define a mechanical stop with the inner rim; a plurality of gas springs operably coupled between the inner rim and the outer rim to provide a gas suspension that allows relative movement between the inner rim and the outer rim; as well as A side wall cover assembly, the side wall cover assembly comprising - an inner sidewall cover coupled to the inner rim and extending radially outwardly toward the outer rim, and - an outer side wall cover connected to the outer rim and extending radially inwardly toward the inner rim and in a sliding overlapping relationship with the inner side wall cover so as to allow relative movement between the inner side wall cover and the outer side wall cover, the outer side wall cover comprising an outer side wall panel and an outer wiper device extending from the outer side wall panel toward the inner side wall cover and in sliding contact with the inner side wall cover, - the inner wall cover comprises an inner wall panel and an inner wiper device extending from the inner wall panel towards the outer wall cover and being in sliding contact with the outer wall cover.

2. The wheel assembly according to claim 1, wherein: The inner wiper device comprises a resilient wiper blade.

3. The wheel assembly according to claim 1, wherein: The outer wiper device comprises a resilient wiper blade.

4. The wheel assembly of claim 1 , comprising an inner ring coupled to the inner rim, extending radially outward from the inner rim and defining a closable gap with an adjacent portion of the outer ring to define a mechanical stop to limit relative movement of the inner rim and the outer rim.

5. The wheel assembly according to claim 4, wherein: The plurality of gas springs have an operating travel that allows the outer ring and the inner ring to define a mechanical stop.

6. The wheel assembly according to claim 1, wherein: The plurality of gas springs are arranged in pairs on opposite sides of the outer ring.

7. The wheel assembly according to claim 1, wherein: The plurality of gas springs radiate axially outwardly from the inner rim to the outer rim.

8. A method of assembling a wheel assembly to be coupled to a wheel hub of a vehicle, the method comprising: coupling a plurality of gas springs between an outer rim and an inner rim to be coupled to the hub to provide a gas suspension that permits relative movement between the inner rim and the outer rim, the wheel assembly comprising an outer ring coupled to the outer rim and extending radially inwardly from the outer rim to define a mechanical stop with the inner rim; coupling an inner sidewall cover of a sidewall cover assembly to the inner rim and extending the inner sidewall cover radially outward toward the outer rim; as well as The outer wall cover of the side wall cover assembly is connected to the outer rim and extends radially inwardly toward the inner rim, and the outer wall cover is in a sliding overlapping relationship with the inner wall cover to allow relative movement between the inner wall cover and the outer wall cover, the outer wall cover includes an outer wall panel and an outer wiper device, the outer wiper device extends from the outer wall panel toward the inner wall cover and is in sliding contact with the inner wall cover, The inner side wall cover comprises an inner side wall panel and an inner wiper device extending from the inner side wall panel toward the outer side wall cover and in sliding contact with the outer side wall cover.

9. The method according to claim 8, wherein: The inner wiper device comprises a resilient wiper blade.

10. The method according to claim 8, wherein: The outer wiper device comprises a resilient wiper blade.

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