Wheel Cover Matrix Assembly for Lightweight Plastic Inserts
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for decorating or finishing vehicle wheels are inefficient, often heavy, difficult to assemble, and can damage the aesthetic cover, while also increasing the weight of the wheel, which is undesirable.
Innovation Solution
A method using a cover matrix with a partial wheel mold and partial cover mold to securely attach plastic inserts to the wheel with threaded fasteners, allowing for quick, standardized, and ergonomic assembly, minimizing human error and enabling automation, while ensuring the inserts are securely fastened without damaging the wheel or inserts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If adhesive methods are used to attach wheel covers, then assembly is simplified, but the assembly process becomes time-consuming and expensive
Solution Approach 1:
The wheel cover is pre-assembled with the spider and inserts on a matrix before being mounted to the wheel. This preliminary assembly on the matrix simplifies the overall manufacturing process while maintaining high assembly speed, as the components are prepared in advance in an organized manner.
Solution Approach 2:
A matrix is introduced as an intermediary device to hold the wheel cover, spider, and inserts during assembly. This matrix facilitates easy assembly by providing a structured platform, yet does not slow down production as it can be quickly released after assembly.
2Shape
If metal appliques are used to decorate wheels, then aesthetic appearance is improved, but wheel weight increases significantly
Solution Approach 1:
The material parameter of the wheel cover is changed from metal to plastic. This parameter change maintains the aesthetic appearance and decorative function while significantly reducing the weight of the wheel assembly.
3Area of stationary object
If foam-in-place process is used to attach covers, then complete surface coverage is achieved, but the process is time-consuming and expensive
Solution Approach 1:
The wheel cover assembly is segmented into discrete components (wheel cover, spider, inserts) that are pre-assembled on a matrix. This segmentation allows for efficient preparation and organization of parts, reducing overall assembly time while maintaining complete surface coverage.
4Adaptability or versatility
If composite style wheels with multiple inserts are assembled, then decorative functionality is improved, but assembly complexity and cost increase
Solution Approach 1:
The matrix serves multiple functions: it holds the wheel cover, supports the spider, positions the inserts, and facilitates assembly. This multi-functionality reduces assembly complexity despite the presence of multiple decorative inserts, as a single device handles all assembly tasks.
Data Source
Figure 1A~1B
Figure 2A
Figure 2B~3
AI summary
The current invention concerns a method of assembling a wheel cover to a wheel (1), thereby providing a covered wheel, comprising the steps of: providing a wheel (1) with a plurality of circumferentially spaced openings (22,23), providing at least one plastic insert (2), suitable as at least partial wheel cover, provided with a series of threaded connector receptacles (21), providing a cover matrix (3), having a shape corresponding roughly to the negative shape of the covered wheel, placing the plastic insert (2) onto the cover matrix (3) in a corresponding insert position, placing the wheel (1) onto the cover matrix (3) in a corresponding wheel position, so that the threaded receptacles communicate with the circumferentially spaced openings (22, 23), and fastening the plastic insert (2) onto the wheel (1) by screwing bolts into the threaded receptacles. The present invention further concerns a cover matrix (3) and the use thereof.