Wheel assemblies including articulated outer rim segments and related methods

Abstract

A wheel assembly includes an inner rim and an outer rim surrounding the inner rim. The outer rim may include outer rim segments, each of which is hingedly coupled to an adjacent outer rim segment in an end-to-end relationship to define an outer rim. The wheel assembly may also include a gas spring operably coupled between the inner rim and the outer rim, and tread members each carried by a respective one of the outer rim segments.

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 to the ground through the wheel. For example, the tires on most vehicles are pneumatic tires. In other words, a typical tire is inflated, for example, with air or other gases such as nitrogen. More specifically, air is injected into the space between the rim and the interior of the tire to cause it to expand.

[0003] During operation, the tires are pneumatically inflated to absorb the forces applied as the vehicle travels over the road surface. The tires and associated inflation pressures may be selected to absorb the aforementioned forces while reducing any deformation. However, in many cases, excessive forces applied to the tires may cause deformation, punctures or blowouts of the tire and / or rim. Typical forces also cause the tread of the tire to wear, while excessive forces may also cause the tread to wear rapidly, which may result in a shortened life of the tire and reduced structural integrity of the wheel.

[0004] In order to address the shortcomings of pneumatic wheels, non-pneumatic wheels have been developed. Non-pneumatic means that air or other gas is not injected to inflate the internal volume of the tire. One approach to 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 main spokes, and the members of each secondary spoke therefore pass on opposite sides of the corresponding pairs of cross braces. 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 rim member may be provided by pivot pins in the outer ends of these arms, which have connecting rods journaled thereto. The connecting rods are pivotally articulated with bent bars, which in turn are pivoted on bracket arms extending inwardly from a part-circular plate, the bracket arms being mounted on the inner periphery of the tire retaining rim.

[0006] Another approach includes a disc between the hub and the outer rim. For example, U.S. Patent No. 1,808,886 to Courtney also discloses a disc or sidewall between the hub and the rim. The disc engages a stud that protrudes from the hub and extends obliquely from the outer flange to the hub. As the wheel turns, the disc assists the wheel tire and rim by resisting any tendency to show sideways due to stress.

[0007] Henap's U.S. Patent No. 1979935 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 equipped with a rod at its extended end.

[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 tip of a hub plate member, the second end being at a position offset from its respective radial axis. The offset position of each spoke is further defined by each spoke being connected to a respective one of the plate member tips at a predetermined angle (e.g., less than 90 degrees) to its radial axis and defining an operatively offset spoke axis that intersects the radial axis of the plate member tip at a predetermined angle.

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

[0010] Despite advances in pneumatic and non-pneumatic tire wheels, there remains a need for improved wheel technology, particularly for use, for example, in large construction or mining vehicles. 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

[0011] The wheel assembly may include an inner rim and an outer rim surrounding the inner rim. The outer rim may include a plurality of outer rim segments, each outer rim segment being hingedly coupled to an adjacent outer rim segment in an end-to-end relationship to define an outer rim. The wheel assembly may also include a plurality of gas springs operably coupled between the inner rim and the outer rim, and a plurality of tread members, each tread member being carried by a corresponding outer rim segment of the outer rim segments.

[0012] The wheel assembly may further comprise a plurality of transverse stops, each of which is coupled between the inner rim and the outer rim. For example, the plurality of transverse stops may comprise a plurality of hinge retainers.

[0013] The plurality of gas springs may include a plurality of inner gas springs and a plurality of outer gas springs. For example, the plurality of gas springs may be coupled between the inner rim and every other outer rim segment in the plurality of outer rim segments.

[0014] The wheel assembly may also include at least one inner ring extending radially outward from the inner rim. The at least one inner ring may include, for example, an inner inner ring and an outer inner ring. For example, the plurality of gas springs may have an operating stroke that allows the at least one inner ring to define a mechanical stop.

[0015] The plurality of gas springs may include a plurality of gas springs with an integrated hydraulic damper. Each of the plurality of gas springs with an integrated hydraulic damper may include a first cylinder and a second cylinder slidable in the first cylinder, and a first seal carried by an end of the second cylinder, the first seal defining a first air chamber and a second air chamber in the first cylinder. Each of the plurality of gas springs with an integrated hydraulic damper may also include an enlarged orifice body and a shaft extending in the first cylinder and into the second cylinder, the shaft defining a hydraulic fluid chamber in the second cylinder, the orifice body connected to the shaft, the orifice body together with the second cylinder defining a hydraulic damper.

[0016] A method aspect relates to a method of manufacturing a wheel assembly. The method may include hingedly coupling a plurality of outer rim segments to adjacent outer rim segments in an end-to-end relationship to define an outer rim. The method may include operably coupling a plurality of gas springs between the inner rim and the outer rim. The method may also include mounting each of a plurality of tread members to a corresponding one of the outer rim segments. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] Figure 1 is a schematic perspective view of a portion of a wheel assembly according to one embodiment.

[0018] Figure 2 yes Figure 1 Schematic side view of a wheel assembly.

[0019] Figure 3 yes Figure 1 Schematic diagram of an outer rim segment of a wheel assembly.

[0020] Figure 4 Includes side wall covers Figure 1 A schematic perspective view of a wheel assembly.

[0021] Figure 5 is a schematic diagram of a portion of a wheel assembly according to another embodiment.

[0022] Figure 6 is a partial cross-sectional view of a gas spring having an associated integral hydraulic damper for use with a wheel assembly according to one embodiment.

[0023] Figure 7 yes Figure 6 Another partial cross-sectional view of a gas spring with an associated integral hydraulic damper.

[0024] Figure 8 yes Figure 6 Another partial cross-sectional view of a gas spring with an associated integral hydraulic damper.

[0025] Fig. 9 yes Figure 6 An enlarged partial cross-sectional view of a portion of a gas spring with an associated integral hydraulic damper.

[0026] Fig.10 is a partial cross-sectional view of a gas spring with an associated integrated hydraulic damper according to another embodiment. DETAILED DESCRIPTION

[0027] SEQ CHAPTER \h \r 1 The present invention will now be described more fully hereinafter with reference to the accompanying drawings, in which preferred embodiments of the present invention are shown. However, the present invention may 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 to make this disclosure comprehensive and complete and to fully convey the scope of the present invention to those skilled in the art. Throughout the embodiments, the same numbers represent the same elements, and in alternative embodiments, primes are used to represent similar elements.

[0028] SEQ CHAPTER \h \r 1First refer to Figure 1-3 The wheel assembly 30 to be coupled to the vehicle hub includes an inner rim 31 to be coupled to the vehicle hub. The inner rim 31 can be coupled to the vehicle hub using fasteners through the fastener receiving channels 24 in the inwardly extending flange ring 25.

[0029] The wheel assembly 30 also includes an outer rim 33 surrounding the inner rim 31, and the outer rim 33 schematically includes outer rim segments 39a-39p. Each outer rim segment 39a-39p is hingedly coupled to an adjacent outer rim segment in an end-to-end relationship to define the outer rim 33. Each outer rim segment 39a-39p has an arcuate shape and, when coupled to an adjacent outer rim segment, shares a common hinge pin 38 to allow adjacent outer rim segments to pivot relative to each other. Illustratively, there are inner and outer hinge pins 38. In some embodiments, the common hinge pin 38 can extend, for example, through the radially inwardly extending sidewall 37, such as across the width of the outer rim, such as between the inner and outer sides. As will be appreciated by those skilled in the art, other and / or additional coupling means can be used between adjacent outer rim segments 39a-39p.

[0030] The inner gas spring 50a and the outer gas spring 50b are operably coupled between the inner rim 31 and the outer rim 33. For example, each gas spring 50a, 50b can be 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 50a, 50b can be a single-acting gas spring. More than one type of gas spring 50a, 50b can be used. The inner gas spring 50a and the outer gas spring 50b can be, for example, an air spring and / or a nitrogen spring. The inner gas spring 50a and the outer gas spring 50b can also include other gases.

[0031] Illustratively, the outer gas spring 50b is coupled between the outer side of the inner rim 31 and the outer side of the outer rim 33 via the mounting member 35, and the inner gas spring 50a is coupled between the inner side of the inner rim and the inner side of the outer rim via the mounting member. More specifically, a given inner and outer gas spring pair 50a, 50b is coupled to a given outer rim segment 39a-39p adjacent to the inner side and the outer side of a given outer rim segment 39a-39p, respectively. For a given outer rim segment 39a-39p, the inner gas spring 50a and the outer gas spring 50b are coupled at opposite ends (i.e., adjacent to the next outer rim segment connected end-to-end).

[0032] The wheel assembly 30 also includes a transverse stop 44 coupled between the inner rim 31 and the outer rim 33, the transverse stop 44 being illustratively in the form of a hinge retainer or scissor-type hinge and extending across the width of the inner rim between the inner side and the outer side. Each transverse stop 44 is coupled to the same outer rim segment 39a-39p as the group or pair of gas springs 50a, 50b. In some embodiments, each transverse stop 44 may not extend between the inner side and the outer side of the inner rim 31, and each transverse stop may be coupled to a different outer rim segment 39a-39p than the gas springs 50a, 50b. As will be appreciated by those skilled in the art, the transverse stop 44 provides increased strength and support for lateral forces that may be applied to the wheel assembly 30.

[0033] The wheel assembly 30 also includes tread members 70a-70p carried by the outer rim 33. More specifically, each tread member 70a-70p is carried by a corresponding outer rim segment in the outer rim segments 39a-39p. Each tread member 70a-70p is sized to be spaced apart from adjacent tread members, for example, in a balanced state. Those skilled in the art will appreciate that the spacing between adjacent tread members 70a-70p may close or become smaller under compression or when the outer rim segments are displaced. In some cases, adjacent tread members 70a-70p may contact each other, thereby defining a mechanical stop therebetween. Each tread member 70a-70p may include, for example, rubber and have a tread pattern. Although a given tread pattern is shown, those skilled in the art will appreciate that, for example, any tread pattern and / or different tread patterns may exist based on the use environment of the wheel assembly.

[0034] Additional references Figure 4 , the wheel assembly 30 may include a sidewall cover 45 extending between the inner rim 31 and the outer rim 33. The sidewall cover 45 may be, for example, rubber or other elastic material that flexes with the compression or displacement of the outer rim segments 39a-39p. Although an inner sidewall cover 45 is shown, those skilled in the art will appreciate that the wheel assembly 30 may also include an outer sidewall cover.

[0035] Now refer to Figure 5 In another embodiment, the wheel assembly 30' may include an outer inner ring 40a' and an inner inner ring 40b' respectively coupled to the outer side and the inner side of the inner rim 31' to define a closable gap 41' together with the adjacent inner portion of the outer rim 33' (more specifically, with the radially inwardly extending sidewall 37'). The inner gas spring 50a' and the outer gas spring 50b' have an operating stroke that allows the inner rings 40a', 40b' to define a mechanical stop. Each of the inner rings 40a', 40b' includes a weight-saving opening 43'. Those skilled in the art will appreciate that having reduced weight can increase the fuel efficiency of the vehicle and / or can increase the life of the wheel assembly 30. Hinge pin 38', fastener receiving passage 24' within inwardly extending flange ring 25', tread members 70a'-70i', outer rim segments 39a'-39i' and lateral stop 44' are similar to those described above.

[0036] Now refer to Figure 6-9 In another embodiment, the gas spring is in the form of a gas spring 50a" with an associated integral hydraulic damper. Similar to the gas spring embodiments described above, the gas spring 50a" with an associated integral hydraulic damper has an operating stroke that allows the outer wheel rim to define a mechanical stop. As will be appreciated by those skilled in the art, the gas spring 50a" with an associated integral hydraulic damper functions similarly to a gas spring and a hydraulic damper to provide suspension and to provide damping.

[0037] Each gas spring 50a" having an associated integrated hydraulic damper includes a first cylinder 51a" and a second cylinder 51b". The second cylinder 51b" is slidable within the first cylinder 51a". In other words, the second cylinder 51b" may be conceptually considered to be a piston movable within the first cylinder 51a".

[0038] The first seal 56" is carried by the end of the second cylinder body 51b". The first seal 56" defines a first air chamber 54a" and a second air chamber 54b" within the first cylinder body 51a". The shaft 62" is connected to one end of the first cylinder body 51a", extends within the first cylinder body and enters the second cylinder body 51b". The shaft 62" defines a hydraulic fluid chamber 63" within the second cylinder body 51b". Each gas spring 50a" with an associated integral hydraulic damper also includes an enlarged orifice body 68", which is connected to the shaft 62" to define a hydraulic damper together with the second cylinder body 51b". The enlarged orifice body 68" has an orifice 69" therein to allow hydraulic fluid to flow therethrough. Although three orifices 69" are shown, there may be any number of orifices.

[0039] A flow restrictor 66" is carried within the second cylinder body 51b". The flow restrictor 66" illustratively includes an orifice 67" therein to allow hydraulic fluid to pass therethrough.

[0040] The gas ports 57a", 57b" are respectively coupled to the first and second gas chambers 54a", 54b" of each gas spring 50a" having an associated integral hydraulic damper. The hydraulic fluid port 57c" is coupled to the second cylinder 51b". Although two gas ports and one hydraulic fluid port are shown, those skilled in the art will appreciate that there may be any greater number of gas and hydraulic fluid ports 57a"- 57c".

[0041] Each gas spring 50a″ with an associated integrated hydraulic damper also includes a first mounting bracket 53a″ and a second mounting bracket 53b″ respectively connected to the first cylinder body 51a″ and the second cylinder body 51b″. The first mounting bracket 53a″ and the second mounting bracket 53b″ are similar to the above-mentioned mounting brackets and are used to mount the gas spring 50a″ with an associated integrated hydraulic damper between the inner rim and the outer rim.

[0042] Those skilled in the art will appreciate that the gas spring 50a″ with an associated integrated hydraulic damper can advantageously provide gas suspension and damper functionality while conserving space within the wheel assembly (i.e., between the inner rim and the outer rim). More specifically, as will be appreciated by those skilled in the art, the gas spring 50a″ with an associated integrated hydraulic damper provides such functionality via a Kelvin connection mechanism.

[0043] Briefly refer to Fig.10 In another embodiment, the shaft 62''', the first seal 56''', one end of the first cylinder 51a''' and the end of the second cylinder 51b''' opposite the first seal may be threaded. By providing threads on the ends of the shaft 62''', the first seal 56''' and the first and second cylinders 51a''', 51b''', the gas spring 50a''' with an associated integral hydraulic damper may be adjusted to a desired response relative to the spring and damper. The volume compensator (e.g., in the form of a reservoir and diaphragm, not shown) may be spring loaded, in which case a charging post may not be ideal. Other elements shown but not specifically described, such as the first cylinder body 51a", the enlarged orifice body 68" and associated orifice 69", the first air chamber 54a" and the second air chamber 54b", the second cylinder wall 66" and the associated orifice 67", the hydraulic fluid chamber 63", the ports 57a"-57c", and the first and second mounting brackets 53a", 53b" are similar to those described above. Further details of a wheel assembly including a gas spring 50a" with an associated integral hydraulic damper are described in U.S. Patent Application No. 17 / 693,373, the entire contents of which are incorporated herein by reference.

[0044] The method aspect relates to a method of manufacturing a wheel assembly 30. The method may include hingedly coupling a plurality of outer rim segments 39a-39p in an end-to-end relationship to adjacent outer rim segments to define an outer rim 33. The method may include operably coupling a plurality of gas springs 50a, 50b between the inner rim and the outer rim. The method may also include mounting each of a plurality of tread members 70a-70p to a corresponding outer rim segment of the outer rim segments 39a-39p.

[0045] Although several embodiments have been described herein, it will be appreciated by those skilled in the art that any one or more elements from one or more embodiments may be used together with any one or more other elements from any other one or more embodiments. Many modifications and other embodiments of the present invention will occur to those skilled in the art with the benefit of the foregoing description and the teachings provided in the associated drawings. Therefore, it will be appreciated that the present invention is not limited to the specific embodiments disclosed, and modifications and embodiments are intended to be included within the scope of the appended claims.

Claims

1. A wheel assembly comprising: Inner rim; an outer rim surrounding the inner rim, the outer rim comprising a plurality of outer rim segments, each outer rim segment being hingeably coupled to an adjacent outer rim segment in end-to-end relationship to define the outer rim; a plurality of gas springs operably coupled between the inner rim and the outer rim; and A plurality of tread members are provided, each tread member being carried by a respective outer rim segment of the plurality of outer rim segments.

2. The wheel assembly according to claim 1, characterized in that Also included is a plurality of lateral stops, each lateral stop coupled between the inner rim and the outer rim.

3. The wheel assembly according to claim 2, wherein: The plurality of lateral stops includes a plurality of hinge retainers.

4. The wheel assembly according to claim 1, wherein: The plurality of gas springs include a plurality of inner gas springs and a plurality of outer gas springs.

5. The wheel assembly according to claim 1, characterized in that: The plurality of gas springs are coupled between the inner rim and every other outer rim segment of the plurality of outer rim segments.

6. The wheel assembly according to claim 1, characterized in that: Also included is at least one inner ring extending radially outward from the inner rim.

7. The wheel assembly according to claim 6, wherein: The at least one inner ring includes an inner inner ring and an outer inner ring.

8. The wheel assembly according to claim 6, characterized in that: Each of the plurality of gas springs has an operating travel that allows the at least one inner ring to define a mechanical stop.

9. The wheel assembly according to claim 1, wherein: The plurality of gas springs include a plurality of gas springs having integral hydraulic dampers.

10. The wheel assembly according to claim 1, characterized in that Each of the plurality of outer rim segments has an arcuate shape.

11. The wheel assembly according to claim 9, wherein: Each of the plurality of gas springs with an integrated hydraulic damper comprises: a first cylinder and a second cylinder slidable in the first cylinder; a first seal carried by an end of the second cylinder, the first seal defining a first air chamber and a second air chamber within the first cylinder; a shaft extending within the first cylinder and into the second cylinder, the shaft defining a hydraulic fluid chamber within the second cylinder; and An enlarged orifice body coupled to the shaft defines a hydraulic damper with the second cylinder.

12. A wheel assembly comprising: Inner rim; an outer rim surrounding the inner rim, the outer rim comprising a plurality of outer rim segments, each outer rim segment being hingedly coupled to an adjacent outer rim segment in end-to-end relationship to define the outer rim; a plurality of inner and outer gas springs operably coupled between the inner and outer rims; a plurality of transverse stops, each transverse stop coupled between the inner rim and the outer rim; and A plurality of tread members are provided, each tread member being carried by a respective outer rim segment of the plurality of outer rim segments.

13. The wheel assembly according to claim 12, wherein: The plurality of lateral stops includes a plurality of hinge retainers.

14. The wheel assembly according to claim 12, wherein: The plurality of inner gas springs and the plurality of outer gas springs are coupled between the inner rim and every other one of the plurality of outer rim segments.

15. The wheel assembly according to claim 12, wherein: Also included is at least one inner ring extending radially outward from the inner rim.

16. The wheel assembly according to claim 12, wherein: The plurality of inboard gas springs and the plurality of outboard gas springs include a plurality of inboard gas springs and a plurality of outboard gas springs having integrated hydraulic dampers.

17. A method of manufacturing a wheel assembly, comprising: hingedly coupling a plurality of outer rim segments to adjacent outer rim segments in end-to-end relationship to define an outer rim; operably coupling a plurality of gas springs between the inner rim and the outer rim; and Each of a plurality of tread members is mounted on a corresponding one of the outer rim segments.

18. The method according to claim 17, characterized in that Also included is a plurality of lateral stops coupled between the inner rim and the outer rim.

19. The method according to claim 18, wherein: Coupling the plurality of lateral stops includes coupling a plurality of hinge retainers.

20. The method according to claim 17, characterized in that Operably coupling the plurality of gas springs includes operably coupling a plurality of inboard gas springs and a plurality of outboard gas springs.

21. The method according to claim 17, characterized in that Operably coupling a plurality of gas springs includes operably coupling the plurality of gas springs between the inner rim and every other outer rim segment of the plurality of outer rim segments.

22. The method of claim 17, further comprising coupling at least one inner ring to extend radially outward from the inner rim.

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