Method and apparatus for producing a wheel cover and vehicle wheel including such a wheel cover

A method for producing a vehicle wheel cover which is formed separately from and is adapted to be installed onto a vehicle wheel comprising the steps of:

• (a) providing a tooling fixture including a first tooling member, a second tooling member and a third tooling member, the first tooling member including an outer end having a generally rounded surface and an annular groove formed therein, the second tooling member having an outer end having a generally rounded surface which is generally complimentary to the rounded surface of the first tooling member, and the third tooling member having an outer end having a rounded surface which is generally complimentary to the annular groove of the first tooling member;
• (b) providing a wheel cover which is formed separately from and is adapted to be installed onto the associated vehicle wheel, the wheel cover having at least a generally U-shaped preformed outer end and at least one opening formed therein which generally correspond to at least one window formed in the associated vehicle wheel;
• (c) positioning the wheel cover onto the tooling fixture wherein the wheel cover is supported on the first tooling member and spaced apart from the second and third tooling members;
• (d) actuating the tooling fixture whereby the second tooling member is operative to engage and reshape the outer end of the wheel cover to produce a desired outer end shape caused by the action of the rounded surface of the second tooling member engaging and reshaping the outer end of the wheel cover against the annular groove of the first tooling member so as to generally conform to the shape of the annular groove formed in the first tooling member, while a portion of the outer end of the preformed wheel cover is captured between the rounded surface of the outer end of the third tooling member and the rounded surface of the outer end of the first tooling member;
• (e) removing the wheel cover from the tooling fixture for subsequent installation on the associated vehicle wheel;
• and
• (f) applying a decorative finish to at least an outer surface of the wheel cover.

A method for producing a vehicle wheel comprising the steps of:

• (a) providing a tooling fixture including at least a first tooling member, a second tooling member and a third tooling member, the first tooling member including an outer end having a generally rounded surface and an annular groove formed therein, the second tooling member having an outer end having a generally rounded surface which is generally complimentary to the rounded surface of the first tooling member, and the third tooling member having an outer end having a rounded surface which is generally complimentary to the annular groove of the first tooling member;
• (b) providing a wheel cover which is formed separately from and is adapted to be installed onto the vehicle wheel, the wheel cover having at least a generally U-shaped preformed outer end and a plurality of openings formed therein which generally correspond to a plurality of windows formed in the associated vehicle wheel;
• (c) positioning the wheel cover onto the tooling fixture wherein the wheel cover is supported on the first tooling member and spaced apart from the second and the third tooling members;
• (d) actuating the tooling fixture whereby the second tooling member is operative to engage and reshape the outer end of the wheel cover to produce a desired outer end shape caused by the action of the rounded surface of the second tooling member engaging and reshaping the outer end of the wheel cover against the annular groove of the first tooling member so as to generally conform to the shape of the annular groove formed in the first tooling member, while a portion of the outer end of the preformed wheel cover is captured between the rounded surface of the outer end of the third tooling member and the rounded surface of the outer end of the first tooling member;
• (e) removing the wheel cover from the tooling fixture;
• (f) providing a vehicle wheel having an outboard tire bead seat retaining flange having a groove formed in an outer peripheral end thereof;
• (g) assembling the wheel cover to the vehicle wheel wherein during assembly the outer end of the wheel cover is initially biased open as the wheel cover is initially assembled onto the outer end and then the outer end of the wheel cover returns to nearly its original shape as the outer end of the wheel cover is retained in the groove in a mechanical lock-like manner.