Vehicle wheel and method of manufacturing a vehicle wheel

Abstract

Vehicle wheels and methods of making vehicle wheels are provided. A vehicle wheel includes a generally annular first region, a second region, and a flange extension. The first region includes an inner surface and an outer surface, the outer surface including a tire bead seat. The second region extends radially inward from the first region. The second region is configured to be mounted to a vehicle wheel axle. The flange extension extends from the first region in a direction away from the second region. The flange extension includes a first extension end integral with the first region, a second extension end, and an elongated portion extending between the first extension end and the second extension end. The elongated portion includes a first portion having a thickness less than the second extension end.

Description

[0001] priority

[0002] This application claims priority to U.S. Provisional Patent Application No. 62 / 967,675, filed January 30, 2020, which is incorporated herein by reference in its entirety. Invention Field

[0003] This disclosure relates to vehicle wheels and methods for manufacturing vehicle wheels. Background Technology

[0004] The weight of vehicle wheels can be reduced by decreasing their thickness. Additionally, it may be necessary to connect external components to the vehicle wheels. Currently, we face challenges related to reducing vehicle wheel thickness and connecting external components to the vehicle wheels. Summary of the Invention

[0005] According to one aspect of this disclosure, a vehicle wheel is provided. The vehicle wheel includes a generally annular first region, a second region, and a flange extension. The first region includes an inner surface and an outer surface, the outer surface including a tire bead seat. The second region extends radially inward from the first region. The second region is configured to be mounted to a vehicle axle. The flange extension extends from the first region in a direction away from the second region. The flange extension includes a first extension end integral with the first region, a second extension end, and an elongated portion extending between the first extension end and the second extension end. The elongated portion includes a first portion with a thickness less than the second extension end.

[0006] According to another aspect of this disclosure, a method for manufacturing a vehicle wheel is provided. The method includes providing the vehicle wheel by means of at least one of the following: forming, curing, forging, casting, and additive manufacturing. The vehicle wheel comprises one or more of metals, metal alloys, and composite materials. The vehicle wheel includes a generally annular first region, a second region, and a flange extension. The first region includes an inner surface and an outer surface, the outer surface including a tire bead seat. The second region extends radially inward from the first region. The second region is configured to be mounted to a vehicle axle. The flange extension extends from the first region in a direction away from the second region. The flange extension includes a first extension end integral with the first region, a second extension end, and an elongated portion extending between the first extension end and the second extension end. The elongated portion includes a first portion with a thickness less than the second extension end.

[0007] It should be understood that the inventions disclosed and described in this specification are not limited to the aspects summarized in this summary. The foregoing details, as well as other details, will be understood after considering the following detailed description of various non-limiting and non-exhaustive aspects according to this specification. Attached Figure Description

[0008] The features and advantages of the examples, as well as the ways in which they are implemented, will become more apparent and the examples will be better understood by referring to the following description taken in conjunction with the accompanying drawings, wherein:

[0009] Figure 1A This is a front perspective view of a non-limiting embodiment of a vehicle wheel including a flange extension according to the present disclosure;

[0010] Figure 1B yes Figure 1A Rear perspective view of the vehicle's wheels;

[0011] Figure 1C It is along Figure 1A The line lC-lC selected in the middle Figure 1A A cross-sectional view of a vehicle wheel;

[0012] Figure 1D yes Figure 1C Detailed 1D cross-sectional view of the area around the vehicle wheels;

[0013] Figure 2 This is a cross-sectional view of a certain area of ​​a vehicle wheel including mounting clips and components according to a non-limiting embodiment of the present disclosure;

[0014] Figure 3 This is an illustrated side view of a vehicle wheel including at least two mounting clips and components according to this disclosure;

[0015] Figure 4A This is a rear perspective view of a vehicle wheel and components secured to the vehicle wheel by mounting clips according to a non-limiting embodiment of the present disclosure;

[0016] Figure 4B It is along Figure 4A Line 4B-4B selected in the middle Figure 4A A cross-sectional view of a vehicle wheel;

[0017] Figure 4C yes Figure 4A A detailed view of area 4C of the vehicle wheel, with the components, mounting clips, fasteners and clamps hidden in the figure.

[0018] In all the views, corresponding reference numerals indicate corresponding parts. The examples set forth herein illustrate certain embodiments in one manner, and such examples should not be construed as limiting the scope of the appended claims in any way. Detailed Implementation

[0019] Various embodiments are described and illustrated herein to provide a comprehensive understanding of the structure, features, and uses of the disclosed articles and methods. The various embodiments described and illustrated herein are non-limiting and non-exhaustive. Therefore, the invention is not limited to the description of the various non-limiting and non-exhaustive embodiments disclosed herein. Rather, the invention is defined solely by the claims. Features and characteristics shown and / or described in conjunction with the various embodiments may be combined with features and characteristics of other embodiments. Such modifications and changes are intended to be included within the scope of this specification. Thus, the claims may be amended to recite any feature or characteristic expressly or inherently described in this specification or otherwise expressly or inherently supported by this specification. Furthermore, the applicant reserves the right to amend the claims to affirmatively deny any feature or characteristic that may appear in the prior art. The various embodiments disclosed and described in this specification may include, constitute, or substantially constitute features and characteristics as described herein differently.

[0020] Any reference to "various embodiments," "some embodiments," "one embodiment," "embodiment," or similar phrases herein implies that a particular feature, structure, or characteristic described in connection with the example is included in at least one embodiment. Therefore, the appearance of the phrases "in various embodiments," "in some embodiments," "in one embodiment," "in an embodiment," or similar phrases in this specification does not necessarily refer to the same embodiment. Furthermore, in one or more embodiments, the specific features, structures, or characteristics described can be combined in any suitable manner. Therefore, a specific feature, structure, or characteristic shown or described in connection with one embodiment can be combined, in whole or in part, with features, structures, or characteristics of one or more other embodiments without limitation. Such modifications and changes are intended to be included within the scope of embodiments of the invention.

[0021] As used herein, the reference to an element or region "between two other elements or regions" means that the referenced element / region is located between two other elements / regions, but not necessarily in contact with them. Thus, for example, the referenced element "between the first element and the second element" may or may not be directly adjacent to or in contact with the first element and / or the second element, and other elements may be located between the referenced element and the first element and / or the second element.

[0022] The inventors have noted that reducing the thickness of a vehicle wheel can decrease its stiffness. Furthermore, they have found that securely connecting components to the vehicle wheel is challenging. Therefore, this paper provides vehicle wheel features and methods for manufacturing vehicle wheels that can increase the stiffness of the vehicle wheel and / or achieve a secure connection between components and the vehicle wheel.

[0023] Figure 1A-1D Non-limiting embodiments of a vehicle wheel according to the present disclosure are shown. The vehicle wheel 100 includes a first region 102, a second region 112, and a flange extension 110. In various non-limiting embodiments, the vehicle wheel 100 may include the first region 102 (e.g., a rim), the thickness of which is reduced to reduce the weight of the vehicle wheel 100.

[0024] The first region 102 may be generally annular and may include an outer surface 104 and an inner surface 106. The outer surface 104 may include a tire bead seat 128, which may be disposed around the circumference of the outer surface 104 of the first region 102. The tire bead seat 128 allows the tire (e.g., Figure 2 The tire 260 is mounted on it and forms a substantially sealed seal with it. The tire may include any suitable size for mounting on the tire bead seat 128. For example, depending on the size of the tire bead seat 128, the tire may include sizes 11R22.5, 295 / 75R22.5, 11R24.5, 285 / 75R24.5, or other suitable sizes.

[0025] The first region 102 may include a nominal rim width and a nominal rim diameter configured to accommodate a tire. In various non-limiting embodiments, the nominal rim width w that the first region 102 may include can range from 1 inch (2.54 mm) to 100 inches (2540 mm), such as 6 inches (152.4 mm) to 24 inches (609.6 mm) or 6 inches (152.4 mm) to 12 inches (304.8 mm), or 5.5 inches (139.7 mm) to 17 inches (431.8 mm). For example, and not limited to, in some non-limiting embodiments, the nominal rim width w of the first region 102 may be 8.25 inches (209.6 mm) or 11 inches (279.4 mm).

[0026] In various non-limiting embodiments, the first region 102 may include a nominal rim diameter d1 ranging from 1 inch (2.54 mm) to 200 inches (5080 mm), such as 14 inches (406.4 mm) to 25 inches (635 mm), 19 inches (482.6 mm) to 25 inches (635 mm), or 16 inches (406.4 mm) to 24 inches (609.6 mm). For example, but not limited to, in some non-limiting embodiments, the nominal rim diameter d1 of the first region 102 may be 22.5 inches (571.5 mm) or 24.5 inches (622.3 mm).

[0027] In various non-limiting embodiments, the first region 102 may include a valve stem mount 108. The valve stem mount 108 may be configured to receive a valve stem 122 to control the transport of gas to and from a tire mounted on the vehicle wheel 100.

[0028] The second region 112 may extend radially inward from the first region 102. In some non-limiting embodiments, the second region 112 is integral with and extends radially inward from the inner surface 106 of the first region 102. In various non-limiting embodiments, the second region 112 extends in a direction substantially perpendicular to the inner surface 106 of the first region 102. The second region 112 may include a first surface 114, a second surface 116, and an opening 118 extending from the first surface 114 to the second surface 116.

[0029] The second region 112 can be configured to be mounted to a vehicle axle (not shown). For example, the opening 118 can be configured to receive at least a portion of the hub of the vehicle axle. Additionally, the hub surface 120 of the second region 112 can be configured to engage the hub of the vehicle axle and facilitate alignment of the vehicle wheel 100 with the hub of the vehicle axle. In various non-limiting embodiments, the hub surface 120 may include a pilot hole adapted to engage a pilot tab of the vehicle axle.

[0030] In various non-limiting embodiments, the second region 112 may include at least two holes 124 extending from the first surface 114 to the second surface 116. Each of the at least two holes 124 may be configured to receive a post on the hub of a vehicle axle. The center point of each hole 124 may be uniformly distributed around a mounting circle. In various non-limiting embodiments, the mounting circle shares a center point with the second region 112. In various non-limiting embodiments, the mounting circle may include a mounting diameter ranging from 1 inch (25.4 mm) to 15 inches (381 mm). For example, the mounting diameter may be 11.25 inches (285.75 mm). In various non-limiting embodiments, the diameter of each hole 124 may range from 0.1 inch (2.54 mm) to 2 inches (50.8 mm). For example, the diameter of each hole 124 may be 1.023 inches (26 mm). In various non-limiting embodiments, the second region 112 may include ten holes 124.

[0031] In various non-limiting embodiments, the second region 112 may include at least two peripheral openings 126 disposed around the periphery 112a of the second region 112 near the proximal end of the first region 102. The at least two peripheral openings 126 may reduce the weight of the vehicle wheel 100. In various non-limiting embodiments, the second region 112 may include ten peripheral openings 126. In various non-limiting embodiments, the peripheral openings 126 may be offset from the holes 124 disposed around the second region 112 (e.g., ...). Figure 1A (as shown), or it can be arranged substantially in a straight line around the second region 112 and the hole 124 (not shown). The offset arrangement of the hole 124 and the peripheral opening 126 (as shown) Figure 1A (As shown) This can increase the rated load of the vehicle wheel 100. In various non-limiting embodiments, each peripheral opening 126 may be uniformly arranged around the peripheral circle. In various non-limiting embodiments, the peripheral circle shares a center point with the second region 112. For example, the peripheral circle may include a peripheral diameter ranging from 2 inches (50.8 mm) to 22 inches (558.8 mm). For example, the peripheral diameter may be 17.3 inches (439.42 mm).

[0032] refer to Figure 1D The flange extension 110 can extend axially from the first region 102. The flange extension 110 includes a first extension end 130 integral with the first region 102, a second extension end 132, and an elongated portion 134 between the first extension end 130 and the second extension end 132. For example, the flange extension 110 can be a feature of a vehicle wheel 100, where the axial extension of the flange extension 110 exceeds the standard wheel flange limit. The flange extension 110 can provide additional stiffness to the vehicle wheel 100 (e.g., increase the stiffness of the vehicle wheel 100) and / or be adapted for component connections. In various non-limiting embodiments, the vehicle wheel 100 may have two flange extensions extending simultaneously from both ends of the first region 102.

[0033] In various non-limiting embodiments, the flange extension 110 may be configured with a geometry (e.g., shape and size) that increases the stiffness of the vehicle wheel 100. For example, the flange extension 110 may include an I-beam-like geometry. For example, the extended portion 134 of the flange extension 110 may include a first portion 136, with a first thickness t1 less than a second thickness t2 of the second extension end 132. Reducing the thickness of the first portion 136 allows the flange extension 110 to function in an I-beam-like manner, enabling it to provide stiffness to the vehicle wheel 100 under bending and shear load conditions relative to the plane in which the flange extension 110 is located. Furthermore, reducing the thickness of the first portion 136 allows the mounting clip (e.g.) Figure 2The mounting clip 244 shown or other devices or components are fixed to the vehicle wheel 100.

[0034] Refer again Figure 1D In various non-limiting embodiments, the second extension 132 may include a surface 138 extending away from the first region 102. In various non-limiting embodiments, the surface 138 may be a substantially flat surface (e.g., Figure 1D (as shown), curved surfaces (not shown), or concave surfaces (as described in this article) Figure 4B (As shown in 456). The second extension 132 can be configured to receive the mounting clip. For example, the second extension 132 may include a tapered member extending from the extension portion 134 to the surface 138. Thus, when the mounting clip passes through the second extension 132, the second extension 132 can facilitate the opening of the resilient mounting clip, and the reduced thickness of the first portion 136 can retract the mounting clip, thereby securing the mounting clip to the flange extension 110 and the vehicle wheel 100.

[0035] The first portion 136 may include a first curved surface 140 extending from the outer surface 104 of the first region 102 and a second curved surface 142 extending from the inner surface 106 of the first region 102. The first and second curved surfaces 140 and 142 may be concave surfaces. The first and second curved surfaces 140 and 142 may reduce the mass of the flange extension while enabling the flange extension to provide rigidity for the vehicle wheel 100 and to accommodate mounting clips.

[0036] The first curved surface 140 may transition to the outer surface 104 of the first region 102 at an inflection point 144, and the second curved surface 142 may transition to the inner surface 106 of the first region 102 along a substantially constant radius of curvature r2. The first curved surface 140 may include a radius of curvature r1, and the second curved surface 142 may include a radius of curvature r2. Each radius of curvature r1 and r2 may range from 0.1 inch (2.54 mm) to 1 inch (25.4 mm), such as 0.1 inch (2.54 mm) to 0.5 inch (12.7 mm), 0.15 inch (3.81 mm) to 0.4 inch (10.16 mm), 0.2 inch (5.08 mm) to 0.4 inch (10.16 mm), or 0.25 inch (6.35 mm) to 0.35 inch (8.89 mm). The radii of curvature r1 and r2 may be the same or different. For example, the radius of curvature r2 may be greater than the radius of curvature r1.

[0037] The flange extension 110 may extend a distance d2 from the tire bead seat 128, allowing the flange extension 110 to accommodate the mounting clip with minimal interference to the tire mounted on the vehicle wheel 100. Furthermore, when the flange extension 110 is mounted on the vehicle axle, the distance d2 is chosen to ensure that the flange extension 110 does not contact or otherwise interfere with any area of ​​the vehicle. For example, the flange extension 110 may extend a distance d2 from the tire bead seat 128, which is at least 0.5 inches (12.7 mm), such as at least 0.6 inches (15.24 mm), at least 0.7 inches (17.78 mm), at least 0.8 inches (20.32 mm), at least 0.9 inches (22.86 mm), or at least 1 inch (25.4 mm). The flange extension 110 may extend from the tire bead seat 128 by a distance d2, which is no greater than 2 inches (50.8 mm), such as no greater than 1.5 inches (38.1 mm), no greater than 1 inch (25.4 mm), no greater than 0.9 inches (22.86 mm), no greater than 0.8 inches (20.32 mm), or no greater than 0.7 inches (17.78 mm). In various non-limiting embodiments, the flange extension 110 may extend from the tire bead seat 128 by a distance d2 ranging from 0.5 inches (12.7 mm) to 2 inches (50.8 mm), such as 0.6 inches (15.24 mm) to 1.5 inches (38.1 mm), or 0.8 inches (20.32 mm) to 1 inch (25.4 mm).

[0038] In various non-limiting embodiments, the thickness of the flange extension 110 may vary along its axial length. For example, a first portion 136 of the elongated portion 134 may have a thickness t1, and a second extension end 132 may have a thickness t2. This variable thickness can be adjusted to reduce the weight of the flange extension 110 and / or optimize the connection between the mounting clip and the flange extension 110. For example, the thickness t2 may range from 0.2 inches (5.08 mm) to 1 inch (25.4 mm), such as 0.25 inches (6.35 mm) to 1 inch (25.4 mm), 0.2 inches (5.08 mm) to 0.5 inches (12.7 mm), 0.2 inches (5.08 mm) to 0.4 inches (10.16 mm), or 0.25 inches (6.35 mm) to 0.35 inches (8.89 mm). In various non-limiting embodiments, the thickness t1 can be at least 0.01 inches (0.254 mm), which is less than the thickness t2, such as at least 0.05 inches (1.27 mm), 0.1 inches (2.54 mm), 0.15 inches (3.81 mm), 0.2 inches (5.08 mm), or 0.25 inches (6.35 mm) smaller than the thickness t2.

[0039] The flange extension 110 can be used to efficiently and securely fasten external components to the vehicle wheel 100. For example, the flange extension 110 may include a feature to which the mounting clip 244 and / or component 250 can be operatively coupled. In various non-limiting embodiments, reference is made to... Figure 2 The vehicle wheel 100 may include a component comprising a mounting clip 244, wherein the mounting clip 244 is configured to engage a first portion 136 and is held by a second extension end 132. For example, the mounting clip 244 may include a clamp, a clamping member, a fastener, a retaining ring, or a combination thereof. In various non-limiting embodiments, the mounting clip 244 may be resilient, such that the mounting clip 244 has an opening 248 that can be enlarged to receive the second extension end 132 and allow a first end 246 of the mounting clip 244 to pass through the second extension end 132 to reach the first portion 136 of the extended portion 134. Thereafter, the opening 248 may be reduced in size, such that the mounting clip 244 is held by the second extension end 132 and secured to the flange extension 110.

[0040] The mounting clip 244 can be configured to hold the component 250 near the flange extension 110. For example, the component can be positioned near the flange extension 110, and the mounting clip 244 can engage the first portion 136 and the component 250 to hold the component 250 in a position near the flange extension 110. The component 250 may include one or more of a wheel cover (e.g., a flight shield), a decorative ring, an energy harvesting system, a lighting system, and a wheel balancing system. The component 250 is held in place by a single mounting clip 244 (e.g., ...). Figure 2 (as shown) or two or more mounting clips 244 (e.g.) Figure 3 (As shown) is operably coupled to the vehicle wheels. For example... Figure 3 As shown, the vehicle wheel 100 may include two or more mounting clips 244 configured to engage the first portion 136 and hold the component 250.

[0041] The mounting clip 244 and component 250 can be separate workpieces or a single continuous workpiece. In embodiments where the mounting clip 244 and component are separate workpieces, the mounting clip 244 can hold the component 250 against the vehicle wheel 100 and / or maintain the component 250 in a desired position and / or orientation.

[0042] refer to Figures 4A-4C Fastener 452 can be operatively coupled to each mounting clip 244. For example, as Figure 4BAs shown, each mounting clip 244 may include a hole 244a through which a fastener 452 may pass. The fastener 452 may include a head 452a and a pin 452b. The head 452a may be configured to prevent the pin 452b from fully protruding from the hole 244a. The pin 452b may include threads adapted to engage the threads of the clamp 454. Before the mounting clip 244 is mounted on the flange extension 110, the pin 452b may be at least partially inserted into the opening 248 of the mounting clip 244, and then at least partially inserted into the hole 244a, such that the head 452 is at least partially positioned within the opening 248 of the mounting clip 244.

[0043] After the pin 452b of the fastener 452 is at least partially inserted into the hole 244a, the mounting clip 244 can be secured to the flange extension 110. In various non-limiting embodiments, the flange extension 110 may include a recess 456 adapted to receive the head 452a of each fastener 452. After the mounting clip 244 is secured to the flange extension 110, the recess 456 may inhibit circumferential movement of the head 452a of each fastener 452 along the flange extension 110. In various non-limiting embodiments, the flange extension 110 may include a recessed channel (not shown) configured to receive the head 452a of the fastener 452 such that the mounting clip 244 can slide circumferentially along the flange extension 110 after it is secured to the flange extension 110.

[0044] The component 250 may include holes 458 configured to receive a pin 452b of each fastener 452. The holes 458 may be radially spaced along the periphery of the component 250. The pin 452b of each fastener 452 may be at least partially inserted into the hole 458, and a clamp 454 may be threadedly connected to the pin 452b, such that the component 250 is positioned between the head 452a and the clamp 454.

[0045] Subsequently, the clamp 454 can be tightened with the pin 452b, at least partially securing the component 250 to the mounting clip 244. Therefore, if the mounting clip 244 is secured to the flange extension 110, the component 250 is also secured to the flange extension 110 by the fastener 452 and the clamp 454. In various non-limiting embodiments, at least two sets of components can be used to secure the component 250 to the flange extension 110, wherein each set of components includes the mounting clip 244, the fastener 452, and the clamp 454. For example, as... Figure 4A As shown, the component 250 can be fixed to the flange extension 110 using eight sets of components.

[0046] In various embodiments, the vehicle wheel according to this disclosure may include metal, metal alloy, composite material, or a combination thereof. For example, the vehicle wheel according to this disclosure may include at least one of the following: aluminum, aluminum alloy, titanium, titanium alloy, magnesium, magnesium alloy, iron, iron alloy, and carbon fiber.

[0047] In various embodiments, the vehicle wheel according to this disclosure can be at least one of the following: a bonded wheel, a welded wheel, a formed wheel (e.g., vacuum formed), a cured wheel, a cast wheel, a forged wheel, and an additively manufactured wheel. The vehicle wheel according to this disclosure may have undergone further processing (e.g., lathe processes) to provide the final vehicle wheel.

[0048] In various non-limiting embodiments, the weight of a vehicle wheel according to the present disclosure may be 10 pounds (lb) (4.5 kg), such as at least 25 lb (11.3 kg), at least 35 lb (15.9 kg), or at least 40 lb (18.1 kg). In some embodiments, the weight of a vehicle wheel according to the present disclosure may not exceed 50 lb (22.7 kg), such as not exceed 40 lb (18.1 kg), not exceed 35 lb (15.9 kg), not exceed 25 lb (11.3 kg), or not exceed 10 lb (4.5 kg). In some embodiments, the weight range of a vehicle wheel according to the present disclosure may be from 10 lb (4.5 kg) to 50 lb (22.7 kg), such as from 25 lb (11.3 kg) to 40 lb (18.1 kg).

[0049] In various non-limiting embodiments, the rated load of the vehicle wheel according to this disclosure may be at least 1000 pounds (lb) (453.6 kg), such as at least 5000 lb (2268 kg), at least 9000 lb (4082.3 kg), at least 10000 lb (4535.92 kg), at least 13000 lb (5896.7 kg), or at least 15000 lb (6803.89 kg). In various non-limiting embodiments, the rated load of the vehicle wheel according to this disclosure may not exceed 20000 lb (9071.85 kg), such as not exceeding 15000 lb (6803.89 kg), not exceeding 13000 lb (5896.7 kg), not exceeding 10000 lb (4535.92 kg), not exceeding 9000 lb (4082.3 kg), or not exceeding 5000 lb (2268 kg). In various non-limiting embodiments, the rated load of the vehicle wheel according to this disclosure can be from 1000 lb (453.6 kg) to 20000 lb (9071.85 kg), such as from 5000 lb (2268 kg) to 15000 lb (6803.89 kg) or from 9000 lb (4082.3 kg) to 13000 lb (5896.7 kg). In various non-limiting embodiments, the rated load of the vehicle wheel according to this disclosure can be at least 10000 lb (4535.92 kg), and the vehicle wheel weight can be less than 40 lb (18.1 kg).

[0050] A method for using vehicle wheels according to the present disclosure is provided. The method includes mounting vehicle wheels according to the present disclosure onto a steering axle of a vehicle, a drive axle of a wheel, or a trailer axle of a trailer. The vehicle may include a vehicle weight class ranging from 1 to 8 (e.g., 3 to 8), as defined by the U.S. Federal Highway Administration. For example, in various non-limiting embodiments, the vehicle's gross weight may be at least 10,001 lb (4536.48 kg) or at least 26,000 lb (11,798.4 kg). The vehicle may be, for example, a light, medium, or heavy-duty vehicle (e.g., a medium or heavy-duty vehicle). In various non-limiting embodiments, the vehicle may be a truck (e.g., a pickup truck, a full-size truck, a tractor (e.g., a semi-truck)), a van, or a bus. The vehicle may include at least two axles, such as at least three axles, at least four axles, at least five axles, or at least six axles. In various non-limiting embodiments, the vehicle may include no more than 10 axles, such as no more than 6 axles, no more than 5 axles, no more than 4 axles, or no more than 3 axles. In various non-limiting embodiments, the number of axles that the vehicle may include ranges from 2 to 10.

[0051] The trailer may include a single axle or at least two axles, such as at least three, four, five, or six axles. In various non-limiting embodiments, the trailer may include no more than ten axles, such as no more than six, five, four, or three axles. In various non-limiting embodiments, the trailer may include one to ten axles.

[0052] A method for producing a vehicle wheel according to the present disclosure is also provided. The method includes forming, curing, forging, machining, casting, and / or additive manufacturing at least one of a metal, metal alloy, composite material, or combination thereof to provide a vehicle wheel according to the present disclosure. For example, the vehicle wheel according to the present disclosure can be manufactured by spinning (e.g., rotational extrusion forming). The flange extension of the vehicle wheel can be formed using a lathe. Producing flange extensions having a geometry suitable for lathe forming enables rapid manufacturing of vehicle wheels. In various embodiments, the method of producing a vehicle wheel according to the present disclosure further includes steps other than forming, curing, casting, forging, machining, or additive manufacturing.

[0053] Various aspects of the present invention include, but are not limited to, those listed in the following numbered clauses.

[0054] 1. A vehicle wheel, comprising:

[0055] A generally annular first region, the first region including an inner surface and an outer surface, the outer surface including a tire bead seat;

[0056] A second region, extending radially inwardly from the first region, is configured to be mounted to a vehicle axle; and

[0057] A flange extension, extending from the first region in a direction away from the second region, the flange extension comprising:

[0058] A first extension end that is integral with the first region;

[0059] Second extension end; and

[0060] The elongated portion extends between the first extension end and the second extension end, and the elongated portion includes a first portion with a thickness less than that of the second extension end.

[0061] 2. The vehicle wheel according to Clause 1, wherein the second extended end includes a substantially flat surface extending away from the first region.

[0062] 3. The vehicle wheel according to Clauses 1-2, wherein the first portion includes a first curved surface extending from the outer surface of the first region and a second curved surface extending from the inner surface of the first region.

[0063] 4. The vehicle wheel according to Clause 3, wherein the first and second curved surfaces are concave surfaces.

[0064] 5. The vehicle wheel according to any one of clauses 3-4, wherein the second curved surface transitions to the inner surface of the first region along a substantially constant radius of curvature.

[0065] 6. The vehicle wheel according to any one of clauses 3-5, wherein the first curved surface transitions to the outer surface of the first region at the inflection point.

[0066] 7. The vehicle wheel according to any one of clauses 3-6, wherein the first curved surface and the second curved surface each have a radius of curvature ranging from 0.1 inches to 1 inch.

[0067] 8. The vehicle wheel according to Clause 7, wherein the radius of curvature of the second curved surface is greater than the radius of curvature of the first curved surface.

[0068] 9. A vehicle wheel according to any one of Clauses 1-8, wherein the first region includes a nominal rim diameter in the range of 1 inch to 200 inches and a nominal rim width in the range of 1 inch to 100 inches.

[0069] 10. A vehicle wheel according to any one of clauses 1-9, wherein the first region includes a nominal rim diameter in the range of 16 inches to 24 inches and a nominal rim width in the range of 5.5 inches to 17 inches.

[0070] 11. The vehicle wheel according to any one of clauses 1-10, wherein the flange extends axially from the tire bead assembly on the first region by at least 0.5 inches.

[0071] 12. The vehicle wheel according to any one of clauses 1-11, wherein the thickness of the second extension end is in the range of 0.2 inches to 1 inch.

[0072] 13. The vehicle wheel according to any one of clauses 1-12, wherein the vehicle wheel comprises at least one of metal, metal alloy and composite material.

[0073] 14. The vehicle wheel according to any one of clauses 1-13, further comprising a mounting clip configured to engage the first portion.

[0074] 15. The vehicle wheel as described in Clause 14, wherein the mounting clip includes one or more of a clamp, a clamping element, a fastener, and a retaining ring.

[0075] 16. The vehicle wheel according to any one of clauses 14-15, further comprising a component wherein the mounting clip is configured to hold the component near the flange extension.

[0076] 17. The vehicle wheel as described in Clause 16, wherein the components include a wheel cover, a decorative ring, an energy harvesting system, a lighting system, and a wheel balancing system.

[0077] 18. A vehicle wheel according to any one of clauses 1-17, the vehicle wheel comprising two or more mounting clips configured to engage the first portion.

[0078] 19. A method for producing vehicle wheels, the method comprising:

[0079] Vehicle wheels are provided by methods including at least one of the following: forming, curing, forging, casting, and additive manufacturing, wherein the vehicle wheel comprises one or more of metals, metal alloys, and composite materials, and wherein the vehicle wheel includes:

[0080] A generally annular first region, the first region including an inner surface and an outer surface, the outer surface including a tire bead seat;

[0081] A second region, extending radially inwardly from the first region, is configured to be mounted to a vehicle axle; and

[0082] A flange extension, extending from the first region in a direction away from the second region, the flange extension comprising:

[0083] The first extension end, which is integrated with the first region;

[0084] Second extension end; and

[0085] The elongated portion extends between the first extension end and the second extension end, and the elongated portion includes a first portion with a thickness less than that of the second extension end.

[0086] 20. The method according to Clause 19, wherein the first region includes a nominal rim diameter ranging from 1 inch to 200 inches and a nominal rim width ranging from 1 inch to 100 inches.

[0087] In this specification, unless otherwise indicated, all numerical parameters should be understood to be prefixed and modified in all instances by the term "about," whereby the numerical parameters have the inherent variability of the basic measurement techniques used to determine the parameter values. Each numerical parameter described herein should be interpreted at least according to the number of significant figures reported and by applying general rounding techniques, without attempting to limit the application of principles equivalent to the claims.

[0088] Any numerical range described herein also includes all subranges falling within the described range. For example, the range "1 to 10" includes all subranges between (and including) the described minimum value of 1 and the described maximum value of 10 (i.e., a minimum value equal to or greater than 1 and a maximum value equal to or less than 10). All ranges described herein also include the endpoints of the described range. For example, the range "1 to 10" includes endpoints 1 and 10. Any maximum numerical limit described in this specification is intended to include all lower numerical limits falling within it, and any minimum numerical limit described in this specification is intended to include all higher numerical limits falling within it. Therefore, the applicant reserves the right to amend this specification (including the claims) to expressly describe any subranges falling within the expressly described range. All such ranges are inherently described in this specification.

[0089] Unless otherwise indicated, the grammatical articles “a,” “an,” and “the” are intended to include “at least one” or “one or more” as used herein (even if “at least one” or “one or more” is explicitly used in some instances). Therefore, the aforementioned grammatical articles are used herein to refer to one or more of the specified elements (i.e., “at least one”). Furthermore, unless the context of use requires otherwise, the use of singular nouns includes plural nouns, and the use of plural nouns includes singular nouns.

[0090] Those skilled in the art will recognize that the articles and methods described herein, along with the accompanying discussion, are used as examples for clarity of concept, and various configuration modifications are contemplated. Therefore, as used herein, the set of specific examples / embodiments illustrated and the accompanying discussion are intended to represent their more general categories. In general, the use of any specific paradigm is intended to represent the category of said paradigm, and the exclusion of specific parts, devices, operations / actions, and objects should not be considered limiting. While this disclosure provides descriptions of various specific aspects for the purpose of illustrating aspects of this disclosure and / or the potential applications of this disclosure, it should be understood that changes and modifications will occur to those skilled in the art. Therefore, one or more inventions described herein should not be construed as being at least as broad as claimed, and are not as narrowly limited as the specific illustrative aspects provided herein.

Claims

1. A vehicle wheel comprising: a first region that is generally annular, the first region including an inner surface and an outer surface, the outer surface including a tire bead seat; a second region that extends radially inward from the first region, the second region configured to be mounted to a vehicle wheel axle; and a flange extension that extends from the first region in a direction away from the second region, the flange extension including: a first extension end that is integral with the first region; a second extension end; and an elongated portion that extends between the first extension end and the second extension end, the elongated portion including a first portion having a thickness that is less than the second extension end, wherein the first portion includes a first concave surface that extends from the outer surface of the first region and a second concave surface that extends from the inner surface of the first region. the second extension end includes a substantially flat surface that extends away from the first region.

2. The vehicle wheel of claim 1, wherein, the second concave surface transitions to the inner surface of the first region along a substantially constant radius of curvature.

3. The vehicle wheel of claim 1, wherein, the first concave surface transitions to the outer surface of the first region at a point of inflection.

4. The vehicle wheel of claim 1, wherein, the first and second concave surfaces each include a radius of curvature that ranges from 0.1 inches to 1 inch.

5. The vehicle wheel of claim 1, wherein, the radius of curvature of the second concave surface is greater than the radius of curvature of the first concave surface.

6. The vehicle wheel of claim 5, wherein, the first region includes a nominal rim diameter that ranges from 1 inch to 200 inches and a nominal rim width that ranges from 1 inch to 100 inches.

7. The vehicle wheel of claim 1, wherein, the first region includes a nominal rim diameter that ranges from 16 inches to 24 inches and a nominal rim width that ranges from 5.5 inches to 17 inches.

8. The vehicle wheel of claim 1, wherein, the flange extension extends at least 0.5 inches axially from the tire bead seat on the first region.

9. The vehicle wheel of claim 1, wherein, the thickness of the second extension end ranges from 0.2 inches to 1 inch.

10. The vehicle wheel of claim 1, wherein, the vehicle wheel includes at least one of a metal, a metal alloy, and a composite material.

11. The vehicle wheel of claim 1, wherein, 12. The vehicle wheel of claim 1, further comprising a mounting clip configured to engage the first portion. the mounting clip includes one or more of a clamp, a clip, a fastener, and a snap ring.

13. The vehicle wheel of claim 12, wherein, the mounting clip is configured to retain the component proximate the flange extension.

14. The vehicle wheel of claim 12, further comprising a component wherein, the component includes a wheel cover, a trim ring, an energy harvesting system, a lighting system, and a wheel balancing system.

15. The vehicle wheel of claim 14, wherein, 16. The vehicle wheel of claim 1, the vehicle wheel including two or more mounting clips configured to engage the first portion.

17. A method of producing a vehicle wheel, the method comprising: providing a vehicle wheel that includes one or more of a metal, a metal alloy, and a composite material by a method that includes at least one of: shaping, curing, forging, casting, and additive manufacturing, the vehicle wheel including: a first region that is generally annular, the first region including an inner surface and an outer surface, the outer surface including a tire bead seat; a second region that extends radially inward from the first region, the second region configured to be mounted to a vehicle wheel axle; and ​ a flange extension extending from the first region in a direction away from the second region, the flange extension comprising: a first extension end integral with the first region; a second extension end; and an elongated portion extending between the first extension end and the second extension end, the elongated portion comprising a first portion having a thickness less than the second extension end, wherein the first portion comprises a first concave surface extending from the outer surface of the first region and a second concave surface extending from the inner surface of the first region.

18. The method of claim 17, wherein, the first region comprises a nominal rim diameter ranging from 1 inch to 200 inches and a nominal rim width ranging from 1 inch to 100 inches.

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