WO2006101788A1

WO2006101788A1 - Wheel cladding assembly

Info

Publication number: WO2006101788A1
Application number: PCT/US2006/008803
Authority: WO
Inventors: Dennis Roger Rogers
Original assignee: Florida Production Engineering, Inc.
Priority date: 2005-03-22
Filing date: 2006-03-10
Publication date: 2006-09-28

Abstract

A cladding assembly for a wheel (210). The cladding assembly includes an overlay (220) with a centrally-disposed aperture (225) and a cap (230) designed to fit in the aperture (225). At least one of the overlay (220) and the cap (230) includes a decorative layer to give the wheel a more aesthetically pleasing appearance. The centrally-disposed aperture (225) defines an engagement hub that includes numerous resiliently-biased detents (222) to promote a secure snap-fit connection between the overlay (220) and a wheel (210), while the central cap (230) includes both overlay attachment members (232) and reinforcements (233) for the detents of the overlay. In one embodiment, the former promotes a friction fit between the cap (230) and the overlay (220), while the latter provides a relatively stiff radial support of the detents (222) to ensure adequate detent rigidity, even under elevated temperature operating conditions.

Description

WHEEL CLADDING ASSEMBLY

This invention relates generally to decorative cladding for vehicular wheels, and more particularly to the manufacture of, and attachment by, a cladding assembly to a vehicular wheel to enhance the wheel's aesthetic attributes while maintaining attachment integrity under harsh environmental conditions.

Aesthetic features form an important part of a vehicle's appeal. Outward appearance can be used to distinguish one vehicle over another, and often is a factor enhancing a vehicle's image. One way to distinguish a vehicle's outward appearance is through metallized finishes (such as chrome plating) that tend to make a car, truck, motorcycle or related vehicle more desirable. Such enhancements are commonly applied to a vehicle's wheels. Unfortunately, the manufacture of highly decorative (for example, forged) wheels can become rather expensive. Decorative overlays placed on top of fabricated steel wheels or cast aluminum wheels have proven to be an inexpensive alternative, as the wheels can be coupled to decorative overlays that can be formed into intricate shapes with finishes not feasible under the structural constraints imposed on forged or related wheels. In a typical decorative overlay, a plastic or related resin-based wheel cover is coated with a metallic layer to give the sought-after shiny chrome-like appearance without a significant increase in cost or unsprung weight.

Under the sort of rotational and vibration loading typically encountered in a vehicular environment, fasteners, such as resilient snap-fit extensions on the back (inward- facing) surface of a wheel cover, are often employed to keep the cover affixed to the wheel. These snap-fit fasteners are integrally formed with the wheel cover. Other resilient fasteners, forming a friction-fit rather than a snap-fit, have also been used. In an alternative to snap-fit and friction-fit fasteners, high-strength adhesives have also been used to attach wheel covers and cladding to wheels. The use of such adhesives, while potentially beneficial for thermal protection of and acoustic enhancement to wheel covers, necessitates relatively detailed placement and assembly procedures to ensure weight minimization, adequate affixation and dynamic balancing, and with concomitant increases in manufacturing costs. As such, the use of the aforementioned resiliently-biased snap-fit and friction-fit fasteners has enjoyed a prominent place in the wheel cover market.

Nevertheless, the prior art arrangements for securing cladding to vehicle wheels have been somewhat complicated in construction and not necessarily applicable to a wide variety of wheel designs. What is needed is a wheel cover configuration that facilitates simple yet secure placement and retention of lightweight fasteners to vehicular wheels. Moreover, what is needed is such a configuration that can maintain fastener integrity under high temperature conditions.

These needs have been met by the present invention, where a wheel cover (also called cladding) can be affixed to a wheel to ensure a durable, robust connection between the two. In a first aspect of the invention, a wheel cladding assembly is disclosed, including an overlay, numerous detents that are integrally formed with the overlay, and a cap sized to fit within an aperture defined in the overlay. In the present context, components are considered integrally formed not only when they are made from a common piece of material (such as in an as-cast or as-molded state), but also when made from disparate parts that upon assembly become permanently attached to one another through welding, riveting, fusing, bonding, coating, plating or the like. The overlay is configured to cover a wheel substantially, and has axially inward and outward facing surfaces. In the present context, the term "substantially" is utilized to represent the inherent degree of uncertainty that may be attributed to any quantitative comparison, value, measurement, or other representation. As such, it refers to an arrangement of elements or features that, while in theory would be expected to exhibit exact correspondence or behavior, may in practice embody something slightly less than exact. The term also represents the degree by which a quantitative representation may vary from a stated reference without resulting in a change in the basic function of the subject matter at issue. It will be appreciated by those skilled in the art that in addition to the aforementioned aperture (configured, for example to allow access to a wheel hub bore situated underneath the overlay), the overlay may further include a plurality of other openings formed therein for decorative or ventilation purposes. Similar openings may be formed in the overlay to be coextensive with bolt locations in the wheel to allow easy access to lug nuts without requiring removal of the overlay from the wheel. The detents are cantilevered from the overlay to give an extending finger-like projection along an axial direction (or at least possessive of a significant axial component) of the overlay, and are circumferentially spaced about the aperture. The cantilevered structure imparts sufficient flexibility over the length of the detent. The detents each include a proximal end and a distal end, the former adjacent the overlay's inward-facing surface and the latter with an accentuated head, pawl or related protuberance situated away from the inward-facing surface. In a preferred embodiment, the accentuated head extends radially outward in a direction substantially normal to the axially inward extension of the detents to which they are attached. This, plus the cantilevered structure, allows the detents to be radially deformable, while their inherent resiliency biases them such that upon attachment of the overlay to the wheel, the detents engage the wheel (such as at or near the wheel's hub bore) to form a snap-fit connection therebetween, thereby forming a direct contact and affixation of the overlay to the wheel. By directly affixing the overlay to the wheel, there need be no intervening structure between them, although it is still possible to have small amounts of an adhesive, thermal insulation or acoustic treatment material between the two in order to impart other desirable properties to the cladded wheel. It will be further appreciated that such direct contact and affixation results primarily from the snap-fit connection occurring at or around the wheel hub bore.

The cap is sized to fit within the aperture, and includes at least one engaging member in the form of a cap connector that protrudes substantially inward from an inner surface of the cap. The cap also includes numerous detent reinforcements protruding substantially inward from the inner surface of the cap. This way, upon insertion of the cap into the overlay aperture, the detent reinforcements maintain the detents in a radially outward shape, thereby strengthening the snap-fit engagement. In one embodiment, the cap connector and detent reinforcements may be formed from a unitary projecting member extending from the rear or inner surface of the cap. In such form, this single projecting member performs both cap fitting and detent reinforcing functions. In another embodiment, the cap may include a metal ring which effectively backs the detent reinforcements.

Optionally, the cap connector is made up of numerous cap retention tabs spaced around a substantial periphery of the cap to hold the cap to a radially inner circumferential surface formed in the aperture. As with the detents of the overlay, these tabs can be cantilevered in an axially inward-facing direction from the cap. In one form, these tabs may be configured to form a friction fit with the aperture, while in another form, they may define snap-fit connections in a manner similar to the overlay detents, where a pawl or related transverse protuberance may be used to effect such a snap-fit arrangement. Additionally, the detent reinforcements may also be spaced around a substantial periphery of the cap. To maximize radial rigidity of the detents, the detent reinforcements are arranged on the cap such that their maximum resistance to deflection (measured, for example, by their moment of inertia) is substantially along a radially outward-facing direction of the cap. As with the detents on the overlay, the friction-fit tabs that can make up the cap connector can be circumferentially-spaced. In a more particular configuration, each of the cap's detent reinforcements and friction-fit tabs can be spaced in an alternating circumferential pattern on the cap's axially-facing inner surface. To ensure proper alignment between the cap and the detents of the overlay, axially longitudinal grooves can be positioned on a radially inward-facing surface of the detent to facilitate alignment of a radially outward-facing edge of the detent reinforcement. These grooves can be formed from one of many ways, for example, the grooves may be flat-machined to define the inward-facing surface. In another form, the detents are circumferentially spaced such that when viewing the overlay from a rear view, the region of the overlay's aperture takes on a substantially castellated appearance. Furthermore, the detents, by virtue of being circumferentially spaced about the aperture, form a rearward annular extension from the overlay. This annular extension is also formed by a ring-like collar that forms a bridge between adjacent spaced detents. The cap connector, in the form of numerous tabs, contacts the collar. The collar defines a larger radius than the portion of the detent that makes up the axially longitudinal grooves. In such construction, the detents and collar define a stepped aperture inner surface.

In one particular form, one or both of the overlay and the cap can be made from a plastic material. In addition, numerous portions of the cap and overlay and their surfaces (especially the outwardly-facing surfaces configured for viewing when mounted to a wheel) can include surface enhancements to color, finish or the like. By way of example, the surface may be painted, metallized, film-coated or have an in-situ color molded-in. In situations where the surface includes a metallic coating, the coating can form a chrome- like appearance. Similarly, when it is painted, it may be colored to complement that of the vehicle to which the wheel and its cover is attached. One or more of an adhesive, thermal insulating layer or an acoustic treatment may be placed in contact with at least a portion of the axial inward-facing surface of the overlay. The layer may be multifunctional such that a single layer may possess acoustic, thermal insulating and adhesive properties. As previously discussed, small, interstitial amounts of adhesive, thermal insulating or acoustic treatment material are not destructive of a direct attachment of the overlay to the wheel, as it is the snap-fit arrangement between the detents and the wheel that give the cladding assembly its secure connection.

According to another aspect of the present invention, a wheel assembly having a wheel and a decorative cladding is provided. The wheel includes a hub bore through its axial center, where the hub bore defines a radially inward-facing surface with at least one circumferential undercut formed in such surface. The decorative cladding is affixable to the wheel through the undercut, and includes an overlay with an aperture therein. When the wheel and overlay are substantially aligned along their respective axial dimensions, a plurality of snap-fit detents, integrally formed in the overlay, engage the undercut. The detents affix the overlay to the wheel. In addition, a cap, sized to fit within the aperture, includes a detent reinforcement mechanism to strengthen the engagement between the detents and the undercut by maintaining the detents in a radially outward shape. Optionally, the detent reinforcement mechanism further comprises numerous stiffening ribs. In a particular construction, the stiffening ribs extend edgewise along a radial dimension of the cap. In addition, the undercut can be at the innermost part of the hub bore's radially inward-facing surface such that it forms where the axial and radial innermost surfaces meet, in effect forming a ledge on an axially inward-facing surface of the wheel.

According to yet another aspect of the invention, a wheel cover assembly is disclosed. The assembly includes an overlay and a cap. The overlay defines a front surface configured to be viewed and a rear surface configured to face a front surface of a wheel. Furthermore, the overlay includes numerous integrally-formed detents arranged about a substantially central aperture formed through the overlay. Each of the detents extends axially rearward and includes a resiliently-biased pawl with which to engage one or more surfaces of the wheel. The cap can be placed within the overlay's aperture, and has a front surface configured to be viewed. The cap also includes a rear surface, substantially opposite the front surface. The cap includes numerous spaced, resilient cap retention tabs and spaced detent reinforcements. Both are placed to form a substantial annular periphery about the rear surface of the cap. The tabs define a circumference such that upon insertion of the cap into the aperture, the tabs form one or more of a friction-fit or a snap-fit engagement with the aperture. Optionally, the detent reinforcements are spaced in an alternating pattern with the cap retention tabs. Moreover, the detent reinforcements and the cap retention tabs each define an elongate dimension such that the elongate dimension of the detent reinforcements extend substantially radially, while the elongate dimension of the cap retention tabs extend substantially circumferentially.

According to still another aspect of the invention, a method of covering a vehicular wheel is disclosed. The method includes providing a wheel, the wheel defining an inner surface, an outer surface and a hub bore extending between the inner and outer surfaces, the outer surface configured to be viewable when mounted onto the vehicle; providing a cladding assembly, the cladding assembly comprising: an overlay with an inner surface configured to face the wheel outer surface, an outer surface and an aperture extending between the inner and outer surfaces, the aperture axially alignable with the hub bore; and a cap configured to fit within the aperture and securing the overlay to the wheel such that a snap-fit engagement between a radially inward portion of the hub bore and the aperture is formed; and securing the cap to the overlay such that at least a portion of the cap provides radial reinforcement of the snap-fit engagement.

Optionally, the method further includes placing a layer of material between at least a portion of the overlay inner surface and the wheel outer surface. As with the previous aspects, the layer of material may be a thermal insulation layer, adhesive layer, acoustic treatment or a combination of the above. The method may further comprise placing a decorative layer, such as a metallic layer, to give, for example, a chrome finish appearance to at least a portion of the wheel outer surface. Likewise, inward-facing components, such as the detents, tabs and detent reinforcements can be coated with a metallic layer or other decorative layer. It will be understood by those skilled in the art that such components may be masked off to avoid coating, if so desired. The securing of the overlay to the wheel may further comprise deformably inserting a plurality of circumferentially spaced cantilevered detents into the hub bore. At some point during the insertion, pawls formed on the detents engage an undercut formed in a radially inward surface of the hub bore, the snap-fit engagement is effected. In one form, the undercut can form a ledge at the location on the hub bore where the radial and axial innermost surfaces meet. In another, the undercut can constitute a peripheral groove formed in the radial innermost surface. Securing the cap to the overlay may further comprise aligning a plurality of circumferentially spaced detent reinforcements disposed on the cap. In this way, the reinforcements maintain the detents in a radially outward shape. Although the use of a hub cap in conjunction with the wheel cover is desirable, there is no requirement that such a cap be present. Thus, according to yet another aspect of the invention, a wheel cover may include an axial outward-facing surface defining a centrally-disposed aperture and a plurality of lug-receiving apertures, and an axial inward- facing surface with numerous integrally formed cantilevered detents. The lug-receiving apertures substantially circumscribe the centrally-disposed aperture, while the detents are placed adjacent the centrally-disposed aperture and radially inward of the lug-receiving apertures. Each of the detents includes an accentuated head to promote resilient snap-fit engagement between a wheel and the wheel cover.

Optionally, the detents are circumferentially disposed about the centrally-disposed aperture, while in a more particular embodiment, the detents define a portion of the centrally-disposed aperture such that the detents help define the shape and size of the aperture. More particularly, the accentuated heads face in a radially outward direction. A hub cap similar to that previously discussed may be placed in the centrally-disposed aperture. In one embodiment, the hub cap includes at least one detent reinforcement that, upon insertion into the centrally-disposed aperture of the wheel cover, strengthens the snap-fit connection. The axial outward-facing surface of the wheel may further define numerous decorative apertures that are, for example, situated radially outward relative to the lug-receiving apertures. In another form, the detents are sized to engage a radially inward-facing surface of the wheel.

FIG. 1 is an exploded view of a wheel assembly as practiced by the prior art, where the wheel is mounted to an automobile, and is covered by an overlay and cap;

FIG. 2 is a rear perspective view of a cladding overlay according to an aspect of the present invention, showing a centrally-disposed aperture formed through the overlay with a plurality of detents used to attach the overlay to a wheel; FIG. 3 is a front perspective view of a cladding overlay according to an aspect of the present invention attached to an automotive wheel;

FIG. 4 is a rear perspective close-up detail of the overlay attached to the wheel of FIG. 3;

FIG. 5 is a front perspective view of a cladding cap according to an aspect of the present invention, showing cap connectors and detent reinforcements extending from a rear surface thereof;

FIG. 6 is a rear perspective view of the cladding cap of FIG. 5, showing how the outermost radial reaches of the cap connectors and detent reinforcements define a substantial periphery around the cap's rear surface;

FIG. 7 is a rear perspective view of the cap of FIGS. 5 and 6 placed within the aperture defined in the overlay of FIG. 2, showing how the cap's detent reinforcements abut the radially inward-facing surfaces of the detents, as well as how the cap connectors fit against a substantial remainder of the inner circumferential surface of the aperture formed in the overlay; and

FIG. 8. is an exploded view of an automotive wheel assembly, where the wheel is mounted to an automobile, and is covered by a cladding and cap as practiced by the present invention.

FIG. 1 shows an exploded view of a prior art version of a wheel assembly 100 with wheel 110, wheel cover 120 and hub cap 130, all mounted to an automotive hub 140. It will be appreciated by those skilled in the art that the term "assembly", which generally includes two or more components in combination with one another to form a larger device, may include some or all of the aforementioned components. For example, subsequent recitations to an assembly may or may not include the wheel 110, and the meaning of the word will be readily apparent from the context. A tire 150 is mounted onto the wheel 110, while a central bore region 160 is formed in wheel 110 to allow placement of lug- receiving holes 162 for connection of a web 166 of the central bore region 160 to corresponding holes of a hub formed at the end of an axle (neither of which are shown). Lugs (not shown) placed through the aligned holes and accompanying nuts (not shown) secure the wheel 110 to the hub. A nut 164 is used to secure the hub to the axle. Both the cover 120 and hub cap 130 may include a series of circumferentially-placed detents 122, 132 (shown presently as snap-fit detents) that extend axially inward from a rear (inward- facing) surface of the cover 120 to affix the cover 120 and hub cap 130 to wheel 110. Cover 120 is placed over the outer face of wheel 110, and can include openings 124 to enhance the appearance of wheel assembly 100, and to provide ventilation for cooling when placed generally coextensive with comparable openings 114 in the wheel 110. In the present context, the face (or outward) surface of the wheel 110 is that which is visible to an observer when the wheel 110 is mounted to an automotive axle. In the case of a motorcycle, since two sides of the wheel are exposed for viewing, there would be two outward-facing surfaces.

Referring to FIGS. 2 through 4, rear and front views of an overlay 220 according to the present invention are shown. In one embodiment, the overlay 220 is made from a plastic or related resin, examples of which may include acrylonitrile-butadiene-styrene (ABS), polycarbonate or a combination thereof, although it will be appreciated by those skilled in the art that the aforementioned resins are merely exemplary and not exhaustive, as other resins with relatively similar structural properties may be used. Referring with particularity to FIG. 2, the manner of affixing overlay 220 to a wheel is shown. The inward-facing (also referred to as the rear or inner) surface 220A faces the outward-facing surface of the wheel. Metallized coating may or may not be placed on the inward-facing surface 220A, depending on whether the overlay 220 was masked prior to coating deposition. A centrally disposed aperture 225 is sized and shaped to fit over a central bore region of the wheel. Aperture 225 is defined by an inwardly-projecting collar 223 that is integrally formed in overlay 220. The collar 223 includes generally smooth radial inner wall segments to facilitate ease of insertion of a cap (shown and described later). Inwardly-projecting detents 222 help define aperture 225 by forming part of the ring-like structure making up collar 223. The collar 223 extends axially inward a shorter distance than the adjacent detents, and includes an axially inward-facing edge that can form a complementary surface with which an optional snap-fit arrangement on the cap can engage. The detents 222 include a proximal end 222A and a distal end 222B, the former establishing an integral formation between the detent 222 and the inward-facing surface 220A, while the latter includes an accentuated head 222C (also referred to as a pawl) to facilitate the snap-fit connection of the detent 222 to a complementary surface of the wheel. The cantilevered nature of the detents 222 provides a spring bias therein such that upon a radial force imposed upon the pawls 222C, the detents 222 will flex to accommodate the force until moved into such a position that the force is removed, at which time the detents 222 will snap back into their original shape. A series of openings

227 are circumferentially spaced about aperture 225 to allow access to lugs (not shown) used to secure the wheel. Each of these openings 227 may be formed at the axially inward end of an integrally formed annular ring 228. The annular ring 228 may include a circumferential rib 228A that forms a hoopwise reinforcing band. Other forms of securing the annular ring 228 to a complementary surface of lug-accepting bores 217 (shown, for example, in FIG. 3) on wheel 210 may be used. For example, snap-fit connectors (not shown) similar to detents 222 may be placed on an axially innermost edge of annular ring

228 to connect to undercuts formed in bores 217.

Referring with particularity to FIG. 3, overlay 220 is mounted to wheel 210. The front (or outward-facing) surface 220B includes a hub 221, spokes 226 and rim 229 to give overlay 220 a generally disk-shaped appearance. Overlay 220 may include a metallized coating or painted-on coating deposited on at least the front surface 220B. In the alternative, overlay 220 may include a or molded-in color. Openings 224 formed between the spokes 226 give the overlay 220 a particular aesthetic attribute, as well as greater access to cooling air. Wheel 210 includes a central body section 212 (shown covered by spokes 226 of overlay 220), and a rim section 214. Together, these two sections form the main part of the exposed surface upon which the overlay 220 is placed. The central body section 212 of wheel 210 defines a plurality of apertures, including a central bore 215 and lug-accepting bores 217 to allow accommodation of lugs and the central wheel hub (neither of which is shown).

In one form, the overlay 220 may form a snug fit with the rim section 214 such that either a groove (not shown) formed in rim section 214 or a doubled-back foldover Kp portion (not shown) of rim section 214 could be used to clamp the outer periphery of overlay 220 in place. The diameter of the overlay 220 can be such that a slight interference fit forms between its outer circumferential edge and the lip or groove formed in the rim section 214. Placing the overlay 220 over the outer surface of the wheel 210 and pressing on the center of the overlay 220 should cause the overlay 220 to flex enough to slightly decrease the diameter of the overlay 220, causing the interference fit to temporarily disappear and thereby allowing the overlay 220 to fit within the Hp or groove of rim section 214. In situations where the overlay 220 may be particularly sensitive to excessive flexure (for example, where a metallized coating is deposited on the overlay 220) used to overcome the aforementioned interference fit, other decorative measures that are highly tolerant of such flexure can be used. By way of example, molded-in coloring and painted-on coloring may be appropriate. In another form, the depth of the detents 222 can be made slightly less than that required to engage an undercut (shown later) of the wheel 210. In this way, it necessitates that the overlay 220 be placed under a preloaded condition (due, for example, to pressing the overlay 220 into engagement with the wheel 210 in a manner similar to that required above to temporarily overcome the interference fit between the overlay 220 and wheel rim 214) to facilitate the connection between the detents 222 and the undercut. In another embodiment, the spokes 226 portion of the overlay 220 that covers wheel spokes (shown, for example, in FIG. 8) can be equipped with snap-fit connectors (not shown) similar to detents 222, thereby promoting a secure connection between the overlay 220 and wheel 210 over a larger portion of the wheel's covered surface. In one form, the connectors are situated on an axially innermost edge of the overlay 220, and can be configured to flex in a circumferential rather than radial direction. Similarly, the connectors could be used to attach the overlay 220 to the wheel 210 along a corresponding pocket or opening 224, where such connectors could be configured to flex in any one of a radial, circumferential or in-between direction.

Referring with particularity to FIG. 4, the details of the connection between the detents 222 formed in aperture 225 of overlay 220 and an undercut 219 formed in wheel 210 are shown. The wheel's central bore region 213 is formed in the center of wheel 210, and is surrounded by lug-receiving holes 217. As can be seen in the figure, the undercut 219 forms a ledge at the meeting of the axially and radially innermost edges of the wheel 210. It will be appreciated that other forms of complementary fit of the wheel 210 and pawls 222C of detents 222 are possible. For example, an inner surface of the wheel's central bore region 213 need not include an undercut 219 with which to accept pawls 222C, as a mere corner edge (not shown) may be sufficient. Similarly, individually fitted undercuts (not shown) may be used. In another form, a circumferential groove (not shown) may be formed in the radially-inward surface of central bore region 213. With regard to the embodiment shown, pawls 222C situated at the distal end 222B form a clamping, snap-fit connection with the ledge of undercut 219. The connection of the detents 222 to the undercut 219 allows the collar 223, with its plurality of generally smooth segments for receiving a complementary surface in the cap (discussed below), to be disposed adjacent the radial innermost surface of central bore region 213. A relatively efficient heat transfer path exists between the metal wheel 210, brakes (not shown) and detents 222 of overlay 220. Without adequate support (for example, radial support), heat from rotational or braking friction might cause the detents 222 to soften and relax, loosening the attachment of the overlay 220 to the wheel 210. To avoid such connection failure, the present invention supplements the detents 222, keeping them in place and keeping the overlay 220 secured to the wheel 210.

Referring next to FIGS. 5 and 6, a cap 230 (which can be used, for example, as a hub cap) is shown. As with the overlay 220, cap 230 is preferably made from ABS, polycarbonate or related polymeric material. The cap is sized to fit with aperture 225 of overlay 220, and includes a rear (inward-facing) surface 230A and a front (outward- facing) surface 230B. As with the front surface 220B of overlay 220, front surface 230B of cap 230 can be metallized to define a chrome-like or related appearance. The rear surface 230A may or may not include metallized coating. Extending axially inward from rear surface 230A of cap 230 is a series of circumferentially spaced detent reinforcements 233 as well as a series of circumferentially spaced cap retention tabs 232. As can be seen, the alignment of the detent reinforcements 233 is such that each is aligned edgewise along a radial dimension of cap 230. Collectively, the cap retention tabs 232 make up a cap connector to be used as an engaging member for securing the cap 230 to the collar 223 formed in aperture 225. The detent reinforcements 233 and cap retention tabs 232 are arranged in an alternating pattern to define a rearward annular projection that evidences a generally castellated structure. As mentioned previously, cap retention tabs 232 can be of snap-fit construction (as shown), including a proximal end 232A integrally formed into the rear surface 230A of cap 230, and an opposing distal end 232B with a radially outward- extending accentuated head 232C. In such a configuration, the tabs 232 possess a resilient bias that is overcome when cap 230 is pushed into collar 223 until brought into cooperative position with the axially inner edge of the collar 223 to allow a flexural return of the tabs to their original shape. Likewise, the tabs 232 may include a friction-fit distal end (not shown) without pawls or related accentuated heads. Cap retention tabs 232 may further include an axially-oriented spine 232D for additional resistance to radially inward flexing.

FIG. 7 shows a rear perspective view of the interconnection of the cap 230 to overlay 220. The supplemental reinforcement of the detents 222 results from the contact of the radially outmost edge of detent reinforcements 233 with the radially innermost surface of the detents 222. To promote cap-to-overlay alignment, the knife-edge termination can be axially aligned in a groove 222D formed between two axial ribs 222E on the radially-inward surface of the detents 222. Collar 223 is shown abutting cap retention tabs 232, while the accentuated heads 232C form a snap-fit engagement with an edge formed by the axially inward surface of collar 223. In an alternate embodiment, a friction-fit between the cap retention tabs 232 and the collar 223 should be sufficient to maintain connection between the cap 230 and the aperture 225 formed in overlay 220. In either configuration, the radial outward expansion of cap 230 attendant to a significant absorption of heat should operate to keep it firmly secured to complementary surfaces of the overlay 220.

Referring last to FIG. 8, an exploded view of the wheel assembly 200 (including cladding components overlay 220 and cap 230) of the present invention, mountable to an automotive hub 240, is shown. A tire 250 is also mounted onto the wheel 210, while the central bore region 213 is formed in wheel 210 to allow placement of lug-receiving holes 213A for connection of the central bore region 213 to corresponding holes of hub 240 formed at the end of axle 270. Lugs 280 placed through the aligned holes and accompanying nuts 290 secure the wheel 210 to the hub 240. It will be appreciated by those skilled in the art that while cap 230 shown in FIGS. 5, 6 and 8 is of a relatively small diameter (such that it fits within a footprint defined by the central bore region 213), that other sizes and configurations may be used. For example, the central aperture 225 of overlay 220 may define a larger diameter (up to, for example six to eight inches) such that a larger diameter cap can connect to the overlay outside the central bore. In such case, detents placed on the overlay, cap or both could be arranged to snap-fit or friction-fit with pockets or openings formed in the wheel, opening or both.

Having described the invention in detail and by reference to preferred embodiments thereof, it will be apparent that modifications and variations are possible without departing from the scope of the invention defined in the appended claims.

Claims

1. A wheel cladding assembly comprising: an overlay configured to cover a wheel substantially, said overlay defining an axial inward-facing surface and an axial outward-facing surface; a plurality of cantilevered detents integrally formed with said overlay and circumferentially disposed about an aperture defined therein, each of said detents comprising a proximal end adjacent said overlay and a distal end including an accentuated head disposed thereon, said detents protruding axially inward from said inner surface to provide a radially deformable bias such that upon attachment of said overlay to said wheel, said detents resiliently engage said wheel to form a snap-fit connection between said accentuated heads and said wheel; and a cap sized to fit within said aperture, said cap comprising: at least one cap connector protruding substantially inward from an inner surface of said cap, said cap connector configured to hold said cap to at least one of said wheel or a radially inner circumferential surface formed in said aperture; and a plurality of detent reinforcements protruding substantially inward from said inner surface of said cap, said detent reinforcements being spaced around the periphery of said cap and configured upon insertion into said aperture to urge said detents radially outward, thereby strengthening said snap-fit connection.

2. The wheel cladding assembly of claim 1, wherein said cap connector is spaced around a substantial periphery of said cap to hold said cap to a radially inner circumferential surface formed in said aperture.

3. The wheel cladding assembly of claim 2, wherein said cap connector comprises a plurality of friction-fit tabs.

4. The wheel cladding assembly of claim 3, wherein said friction-fit tabs are cantilevered in an axially inward-facing direction from said cap.

5. The wheel cladding assembly of claim 3, wherein said detent reinforcements and said friction-fit tabs are spaced in an alternating circumferential pattern on said inner surface of said cap.

6. The wheel cladding assembly of claim 5, further comprising a receiving groove formed on a radially inward-facing surface of said detents to facilitate alignment of a radially outward-facing edge of said detent reinforcement with a corresponding one of said detents.

7. The wheel cladding assembly of claim 6, wherein said detents are circumferentially spaced about said aperture to form a rearward annular extension from said overlay, said rearward annular extension also formed by a collar intermittently formed between said detents and configured to contact said cap connector, said collar defining a larger radius than a radially innermost projection of said detents such that together, said detents and said collar define a stepped aperture inner surface.

8. The wheel cladding assembly of claim 1, wherein said detent reinforcements are arranged on said cap such that their maximum resistance to deflection is substantially along a radially outward-facing direction.

9. The wheel cladding assembly of claim 1, wherein said overlay comprises a plastic material.

10. The wheel cladding assembly of claim 9, wherein at least said axial outward-facing surface of said overlay further comprises a metallized coating formed thereon.

11. The wheel cladding assembly of claim 10, wherein said metallized layer provides the appearance of a chrome finish.

12. The wheel cladding assembly of claim 1, wherein said cap comprises a plastic material.

13. The wheel cladding assembly of claim 12, wherein at least said axial outward- facing surface of said cap further comprises a metallized coating formed on a surface thereof.

14. The wheel cladding assembly of claim 13, wherein surfaces of said cap connector and said detent reinforcements further comprise a metallized coating formed thereon.

15. The wheel cladding assembly of claim 1, wherein said aperture is formed in a substantial center of said overlay.

16. The wheel cladding assembly of claim 1, wherein said detents are circumferentially spaced to define a substantially castellated wheel hub-engaging portion of said overlay.

17. The wheel cladding assembly of claim 1, further comprising an adhesive layer in contact with at least a portion of said axial inward-facing surface of said overlay.

18. The wheel cladding assembly of claim 1, further comprising a thermal insulating layer in contact with at least a portion of said axial inward-facing surface of said overlay.

19. The wheel cladding assembly of claim 1, further comprising an acoustic treatment layer in contact with at least a portion of said axial inward-facing surface of said overlay.

20. The wheel cladding assembly of claim 19, wherein said acoustic treatment layer is also an adhesive layer and a thermal insulating layer.

21. A wheel assembly comprising: a wheel having a hub bore through an axial center thereof, said hub bore defining a radially inward-facing surface with at least one circumferential undercut formed therein; and a decorative cladding affϊxable to said wheel through said undercut, said decorative cladding comprising: a decorative overlay defining an aperture therein such that upon substantial axial alignment and contact of said wheel to said overlay, a plurality of snap-fit detents integrally formed in said overlay about said aperture engage said undercut to affix said overlay to said wheel; and a cap sized to fit within said aperture, said cap including a detent reinforcement mechanism configured to maintain said detents in a radially outward shape, thereby strengthening said connection between said detents and said undercut.

22. The wheel assembly of claim 21, wherein said detent reinforcement mechanism further comprises a plurality of stiffening ribs.

23. The wheel assembly of claim 22, wherein said stiffening ribs extend edgewise along a radial dimension of said cap.

24. The wheel assembly of claim 21, wherein said at least one undercut forms a ledge on an axially inward-facing surface of said wheel.

25. A wheel cover assembly comprising: an overlay defining a front surface configured to be viewed and a rear surface configured to face a front surface of a wheel, said overlay comprising a plurality of integrally-formed detents arranged about a substantially central aperture formed through said overlay, each of said detents extending axially rearward and including a resiliently- biased pawl with which to engage at least one surface of said wheel; and a cap configured to be placed within said aperture, said cap defining a front surface configured to be viewed with said front surface of said overlay and a rear surface substantially opposite said front surface, said cap comprising: a plurality of spaced resilient cap retention tabs extending from said rear surface of said cap, such that upon insertion of said cap into said aperture, said tabs form at least one of a friction-fit or a snap-fit engagement with said aperture; and a plurality of spaced detent reinforcements extending from said rear surface of said cap, said detent reinforcements configured to maintain said detents in a preferred radial shape.

26. The wheel cover assembly of claim 25, wherein said detent reinforcements are spaced in an alternating pattern with said cap retention tabs.

27. The wheel cover assembly of claim 26, wherein said detent reinforcements and said cap retention tabs each define an elongate dimension such that said elongate dimension of said detent reinforcements extend substantially radially, while said elongate dimension of said cap retention tabs extend substantially circumferentially.

28. A method of covering a vehicular wheel, said method comprising: providing a wheel with an inner surface, an outer surface and a hub bore extending between said inner and outer surfaces; providing a cladding assembly, said cladding assembly comprising an overlay with an inner surface configured to face said wheel outer surface, an outer surface and an aperture extending between said inner and outer surfaces, said aperture axially alignable with said hub bore; and cap configured to fit within said aperture; securing said overlay to said wheel such that a snap-fit engagement between a radially inward portion of said hub bore and said aperture is formed; and securing said cap to said overlay such that at least a portion of said cap provides radial reinforcement of said snap-fit engagement.

29. The method of claim 28, further comprising placing a layer of material between at least a portion of said overlay inner surface and said wheel outer surface.

30. The method of claim 29, wherein said layer of material is a thermal insulation layer.

31. The method of claim 29, wherein said layer of material is an adhesive layer.

32. The method of claim 29, wherein said layer of material is an acoustic treatment layer.

33. The method of claim 28, further comprising placing a decorative layer on at least a portion of said wheel outer surface

34. The method of claim 33, wherein said decorative layer comprises a metallic layer.

35. The method of claim 34, wherein said metallic layer provides the appearance of a chrome finish.

36. The method of claim 28, wherein said securing said overlay to said wheel further comprises deformably inserting a plurality of circumferentially spaced cantilevered detents integrally formed about said aperture into said hub bore such that upon introduction of pawls formed on said detents into an undercut formed in a radially inward surface of said hub bore, said snap-fit engagement is effected.

37. The method of claim 36, wherein said securing said cap to said overlay further comprises aligning a plurality of circumferentially spaced detent reinforcements disposed on said cap such that said reinforcements maintain said detents in a radially outward shape.

38. A wheel cover comprising: an axial outward-facing surface defining a centrally-disposed aperture and a plurality of lug-receiving apertures therein such that said lug-receiving apertures substantially circumscribe said centrally-disposed aperture; and an axial inward-facing surface comprising a plurality of cantilevered detents extending therefrom and integrally formed therein, said detents disposed adjacent said centrally-disposed aperture and radially inward of said lug-receiving apertures, each of said detents comprising an accentuated head configured to resiliently engage a wheel to form a snap-fit connection therebetween.

39. The wheel cover of claim 38, wherein said detents are circumferentially disposed about said centrally-disposed aperture.

40. The wheel cover of claim 39, wherein said accentuated heads face in a radially outward direction.

41. The wheel cover of claim 39, further comprising a hub cap placeable in said centrally-disposed aperture.

42. The wheel cover of claim 41, wherein said hub cap comprises at least one detent reinforcement that, upon insertion into said centrally-disposed aperture, strengthens said snap-fit connection.

43. The wheel cover of claim 38, wherein said detents define a portion of said centrally-disposed aperture.

44. The wheel cover of claim 38, wherein said axial outward-facing surface further defines a plurality of decorative apertures formed therein.

45. The wheel cover of claim 44, wherein said plurality of decorative apertures are situated radially outward relative to said lug-receiving apertures.

46. The wheel cover of claim 38, wherein said detents are sized to engage a radially inward-facing surface of said wheel.