BALANCE WEIGHT
Field of the invention
The invention pertains to a method to manufacture a device for balancing a vehicle wheel; this device comprises a fastener for attaching and fixing the device to the vehicle wheel, a plastic body and a weight. The invention also pertains to such a device. The invention further pertains to moulds to manufacture such a device.
Background of the invention
A device for balancing a vehicle wheel is known. Such a device is also called a balance weight. A balance weight is used to dynamically or statically balance a vehicle wheel of, for instance, an automobile, truck, motorcycle or the like. An unbalanced rotating wheel can cause vibrations which can damage the vehicle, have an adverse effect on the performance of the vehicle and adversely affect the comfort of the driver and the passengers. A balance weight for vehicle wheels in principle consists of a weight and means to attach and fix the weight on or onto a portion of the wheel, such as the wheel rim or a spoke, for instance. In the past, the choice of materials was limited by legislation and regulations; the weight of the balance weight was usually made of lead or lead alloys. Lead and some lead alloys have a relatively high specific gravity and possess rheological properties that are well suited to the intended application. Their rigidity, for instance, is such that when subjected to the customary clamping forces, the shape of the contact surface of the balance weight can adapt, to some extent, to the contour of the wheel rim. Moreover, the hardness of lead and some lead alloys is low compared to that of the material from which the wheel is constructed. This reduces the probability of the contact surface of the wheel becoming damaged during the installation or removal of the balance weight. Furthermore, there is only a slight probability of electrolytic corrosion when using lead or lead alloys on metal wheel rims or spokes. Because of their toxic properties, the use of lead and lead alloys is no longer allowed in many countries. This has resulted in the development of lead-free balance weights.
Zinc and iron, whether or not in the form of alloys, are alternatives to lead. A disadvantage of zinc is that it is relatively expensive compared to iron and iron alloys. US 6250721
describes a balance weight made of iron. Iron and iron alloys are relatively hard compared to lead and zinc alloys and are difficult to deform while attaching them to the wheel rim. This gives rise to peak stresses along the contact surface between the balance weight and the wheel rim, which can result in damage to the wheel rim. This applies particularly to light-alloy wheel rims that are less scratch-resistant than steel wheel rims. EP0990096 Bl describes a balance weight consisting of a fastener, in the form of a metal clip, for clamping the balance weight onto the wheel rim, and a weight made of glass, porcelain or ceramic. These materials are not deformable under the clamping forces commonly used and will not adapt themselves to the contour of the wheel rim. When there are hollow spaces along the contact surfaces between the balance weight and the wheel rim, moisture and solid particles can accumulate and promote corrosion.
US2004256909 describes a balance weight consisting of a fastener, of which the shape of the hook portion has been matched to the shape of the edge of the wheel rim, and a plastic body that is injection moulded to the leg portion of the fastener. The plastic body has a hollow cavity in which a weight, such as a bar made of tungsten for instance, can be positioned and fixed. The advantage of tungsten is that it has a relatively high specific gravity but its disadvantage is the relatively high price of the raw material. Moreover, the manufacturing costs of the balance weight are relatively high.
WO2004025139 describes a balance weight that is entirely or partially encased in a coating. One of the purposes of the coating is to prevent the wheel rim from becoming damaged during the fixing and removal of the balance weight and to counteract electrolytic corrosion. A disadvantage of this device is that the application of a coating requires an additional operation that makes the manufacturing process more expensive. EP 1079141 describes a balance weight of which the leg portion of the fastener is connected to a body made of a mixture of a synthetic resin and tungsten powder. It takes advantage of the relatively high specific gravity of tungsten. Mixing the tungsten particles with the much lighter synthetic resin cancels out some of this advantage though. Moreover, as already mentioned, tungsten — whether or not in powder form — is a relatively expensive raw material.
The purpose of the present invention is to provide an inexpensive device for balancing a vehicle wheel by making use of inexpensive raw materials and an inexpensive method for manufacturing the device.
Summary of the invention
The invention provides a method for manufacturing a device for balancing a vehicle wheel; this device comprises a fastener for attaching and fixing the device to the vehicle wheel, a plastic body and a weight, characterised in that the method also comprises placing at least part of the fastener in a mould, placing the weight in the mould and introducing a plastic material into the mould. The advantage of this method is that by introducing a plastic material into the mould, a plastic body is created that connects the fastener to the weight while also encasing the weight in the plastic material. In this manner, two manufacturing steps, involving connecting the fastener to the weight and encasing the weight, are combined.
For the purpose of positioning the fastener and the weight relative to the mould, the mould can be provided with positioning aids. The fastener and the weight can also be provided with positioning aids. Using these positioning aids, the weight and the plastic body can be positioned relative to the fastener in a manner that can be reproduced and that meets the desired accuracy.
The fastener and the weight can also be provided with positioning aids for positioning the fastener and the weight relative to each other. Positioning the fastener and the weight relative to each other is used for an embodiment of the method in which the fastener and the weight are placed in the mould as an assembly.
The invention also provides for a device for balancing a vehicle wheel; this device comprises a fastener for attaching and fixing the device to the vehicle wheel, a plastic body and a weight, characterised in that the fastener is attached to the weight solely by means of the plastic body. In this case, no additional means needs to be added or action undertaken to connect the fastener and the weight to each other or to connect the fastener and the weight to the plastic material.
To achieve a strong connection between the fastener and the weight, the fastener and the weight are positioned relative to each other in such a manner that they do not touch. This
embodiment of the device results in a large contact surface between the fastener and the weight on the one hand and the plastic body on the other. At the same time, this embodiment of the device elirninates the possibility of electrolytic corrosion as a result of contact between the fastener and the weight.
In a preferred embodiment of a device according to the invention, the weight is encased entirely or almost entirely in the plastic body. This prevents damage to the edge of the wheel rim and corrosion of the weight.
The invention also provides moulds for manufacturing a device for balancing vehicle wheels; this device comprises a fastener for attaching and fixing the device to the vehicle wheel, a plastic body and a weight, characterised in that each mould is equipped with positioning aids for positioning the fastener and/or the weight.
Brief description of the drawings
The invention is illustrated below with the aid of three figures. Figure 1 is a perspective view of a device for balancing a vehicle wheel based on prior art technology; Figure 2 is a cross sectional view of this device. Figure 3 is a cross sectional view of a device for balancing a vehicle wheel according to a non-limiting example of an embodiment of the invention.
Embodiments of a method, a device and moulds according to the invention Figures 1 and 2 show a known device 1 for balancing a vehicle wheel. This device 1 consists of a fastener 2 and a weight 3. The fastener 2 serves to attach and fix the device 1 to an unspecified edge of the wheel rim. For this purpose, the fastener 2 is provided with a hook portion 4, the shape of which corresponds to the shape of the edge of the wheel rim. In the case of this prior art device 1, the weight 3 is injection moulded and fixed to the leg portion 5 of the fastener. Figure 3 shows a device 6 according to a non-limiting embodiment of the invention, made up of a fastener 2, a weight 8 and a plastic body 7.
A method in accordance with the invention also comprises placing at least part of the fastener 2 in an unspecified mould, placing the weight 8 in the mould and introducing a plastic material 7 into the mould. In a first embodiment of a method in accordance with the
invention, the fastener 2 and the weight 8 are placed in the mould independently of each other in either an arbitrary or a fixed sequence. In doing so, use is made of unspecified positioning aids that have been affixed to the fastener 2 and/or to the weight 8 and/or to the mould. The fastener and the weight are then fixed in their relative positions. The fixing can, for instance, be achieved by placing the two mould halves against each other and connecting the two mould halves together. After the mould has been closed, a plastic material is injected into the mould by means of injection moulding, whereby the leg portion 5 of the fastener 2 is connected to the weight 8 by means of the plastic material and whereby the weight 8 and at least part of the fastener 2 are encased in the plastic material. To improve the anchoring of the leg portion 5 of the fastener 2 in the plastic body 7, unspecified sections, apertures and/or notches may have been made in the leg portion 5.
In a second embodiment of a method in accordance with the invention, the fastener 2 and the weight 8 are placed in the mould as an assembly. To do this, the weight 8 is first fixed to the leg portion 5 of the fastener 2 in a manner that allows the assembly of the fastener 2 and the weight 8 to be placed in the mould without any change in the position of the weight 8 relative to the fastener 2. To achieve this, the fastener 2 and the weight 8 can be clamped together in some simple manner.
Preferably, the fastener 2 and the weight 8 are positioned in the mould in such a manner that they do not touch each other. The weight 8 can also be placed in the mould in such a manner that the weight does not touch the inside wall of the mould. This is, for instance, possible by using positioning aids that are placed between the weight 8 and the inside wall of the mould; these positioning aids are made of the same material as that of the plastic body 7. In this manner the weight 8 will become completely encased in the plastic body 7 formed after the introduction of the plastic material, while contact with the outside air or the wheel rim is avoided.