# US 9,039,074 B1 · Wheel liner apparatus > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 9,039,074 B1 - Document ID: US9039074B1 - Status: Granted - Kind: B1 - Application number: 13/705,165 - Filed: 2012-12-04 - Granted: 2015-05-26 - Earliest claimed: 2012-12-04 - Applicants: Dan Leuciuc; Alexandru Oltean - Inventors: Dan Leuciuc; Alexandru Oltean - Web page: https://patentgrep.com/patent/US9039074B1 ## CPC - B29C 44/1271: {the preformed parts being partially covered} - B60R 13/0861: {for covering undersurfaces of vehicles, e.g. wheel houses} - B62D 25/16: Mud-guards or wings; Wheel cover panels (equipped with means for freeing wheels or tyres from foreign matter B60S) - B62D 25/163: {Mounting devices} - B62D 29/004: {the metal being over-moulded by the synthetic material, e.g. in a mould} - B29K 2105/04: cellular or porous - B29L 2031/3005: {Body finishings} - B62D 25/161: {Mud-guards made of non-conventional material, e.g. rubber, plastics} - B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00) - B60R: VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR - B62D: MOTOR VEHICLES; TRAILERS (steering, or guiding on a desired track, of agricultural machines or implements A01B69/00; wheels, castors, axles, increasing wheel adhesion B60B; vehicle tyres, tyre inflation or tyre changing B60C; connections between vehicles of a train or the like B60D; vehicles for use on rail and road, amphibious or convertible vehicles B60F; suspension arrangements B60G; heating, cooling, ventilating or other air treating devices B60H; windows, windscreens, non-fixed roofs, doors or similar devices, protective coverings for vehicles not in use B60J; propulsion plant arrangements, auxiliary drives, transmissions, controls, instrumentation or dashboards B60K; electric equipment or propulsion of electrically-propelled vehicles B60L; power supply for electrically-propelled vehicles B60M; passenger accommodation not otherwise provided for B60N; adaptations for load transportation or to carry special loads or objects B60P; arrangement of signalling or lighting devices, the mounting or supporting thereof or circuits therefor, for vehicles in general B60Q; vehicles, vehicle fittings or vehicle parts not otherwise provided for B60R; servicing, cleaning, repairing, supporting, lifting, or manoeuvring, not otherwise provided for, B60S; brake arrangements, brake control systems or parts thereof B60T; air-cushion vehicles B60V; motor-cycles, accessories therefor B62J, B62K; testing of vehicles G01M) - B29K: INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR {MOULDS, } REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS - B29L: INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES ## Abstract A wheel liner comprises a rigid frame with relatively large openings rather than a continuous surface. Non-woven fibers or potential other similar materials which are often less rigid than the frame are inserted over the openings of the frame. The resulting wheel liner is less expensive, lighter, more aesthetically pleasing, and possessing superior sound dampening capabilities than a conventional prior art wheel liner. ## Claims ### Claim 1 A wheel liner apparatus for use on a vehicle to prevent the intrusion of debris into a wheel area of the vehicle, comprising: a plastic frame, said plastic frame including a plurality of openings and a plurality of attachment components, wherein said plurality of attachments components provide for attaching said wheel liner apparatus to the vehicle; and a plurality of non-woven inserts attached to said plastic frame and covering said openings; wherein said wheel liner apparatus is a substantially single-layered wheel liner apparatus; wherein said wheel liner apparatus is formed using an over-molding tool; wherein said plurality of non-woven inserts are a plurality of 3D molded non-woven inserts; and wherein said plastic frame is molded around said non-woven inserts. ### Claim 2 (depends on 1) The wheel liner apparatus of claim 1, said frame including a plurality of boundary surfaces surrounding said openings, said plurality of non-woven inserts including a plurality of overlap areas, wherein said boundary surfaces are mated to said plurality of overlap areas, wherein no other portions of said frame overlaps with said plurality of non-woven inserts, and wherein said over-molding tool includes a retention feature built into a core that allows for precise positioning and retention of said non-woven inserts prior to a closing of said over-molding tool. ### Claim 3 (depends on 1) The wheel liner apparatus of claim 1, wherein said wheel liner apparatus is comprised of a plurality of separate subassemblies that provide for being installed separately. ### Claim 4 (depends on 1) The wheel liner apparatus of claim 1, wherein the over-molding tool includes a needle, a needle holder, and a threaded insert to secure the position of said non-woven inserts. ### Claim 5 (depends on 1) The wheel liner apparatus of claim 1, wherein said non-woven inserts are less rigid than said plastic frame, and wherein said plurality of openings are completely filled by said plurality of inserts, and wherein said plurality of inserts comprise the only portion of said wheel liner apparatus within said plurality of openings. ### Claim 6 (depends on 1) The wheel liner apparatus of claim 1, wherein said openings on said plastic frame do not include a rubber border, wherein said frame is a single-layered frame, and wherein said frame fully surrounds said plurality of openings. ### Claim 7 (depends on 1) The wheel liner apparatus of claim 1, wherein said non-woven inserts are formed from a multi-cavity tool. ### Claim 8 (depends on 1) The wheel liner apparatus of claim 1, wherein said non-woven inserts are comprised between about 40%-60% renewable fiber. ### Claim 9 (depends on 1) The wheel liner apparatus of claim 1, wherein an overlap area of said plastic frame and said non-woven insert does not include any steps, and wherein there is a thickness variation between said non-woven insert and said plastic frame. ### Claim 10 (depends on 1) The wheel liner apparatus of claim 1, wherein said non-woven inserts are thermoformed prior to being cut and fixed to said plastic frame. ### Claim 11 (depends on 1) The wheel liner apparatus of claim 1, wherein said non-woven inserts comprise at least about 65% of the surface area of said wheel liner apparatus. ### Claim 12 (depends on 1) The wheel liner apparatus of claim 1, wherein said plastic frame includes a groove surrounding at least one said opening, and where at least one said non-woven insert includes an overlap area configured to be positioned over said groove. ### Claim 13 (depends on 1) The wheel liner apparatus of claim 1, wherein a a plurality of needles are used to position said non-woven inserts with respect to said over-molding tool. ### Claim 14 (depends on 1) The wheel liner apparatus of claim 1, wherein said non-woven inserts are comprised primarily of fiber. ### Claim 15 (depends on 1) The wheel liner apparatus of claim 1, wherein said non-woven inserts are thermoformed prior to insertion in said over-molding injection molding tool. ### Claim 16 A wheel liner apparatus for use on a vehicle to prevent the intrusion of debris into a wheel area of the vehicle, comprising: a frame, said frame including a plurality of openings and a plurality of attachment components, wherein said plurality of attachments components provide for attaching said wheel liner apparatus to the vehicle; and a plurality of inserts permanently attached to said frame and positioned to cover said openings; wherein said inserts are comprised of a material that is less dense and less rigid than said frame; wherein said inserts are a plurality of 3D molded non-woven inserts; wherein said frame is a single-layered frame; wherein said wheel liner apparatus is a substantially single-layered wheel liner apparatus; wherein said wheel liner apparatus is formed using an over-molding tool; and wherein said plastic frame is molded around said insert. ### Claim 17 (depends on 16) The wheel liner apparatus of claim 16, further comprising an overlap area where at least a portion of at last one said insert overlaps with said frame, and wherein said attachment components are identical to a conventional plastic wheel liner apparatus. ### Claim 18 (depends on 16) The wheel liner apparatus of claim 16, wherein said inserts are permanently attached to said frame. ### Claim 19 A method for manufacturing a substantially single-layered wheel liner apparatus that is comprised of a plastic frame that includes a plurality of openings filled by a plurality of inserts, said method, comprising: cutting a portion of raw material from a roll; heating the cut portion; placing the heated portion in a mold to form a sheet of inserts; removing the inserts from the sheet; trimming the edges of the inserts removed from the sheet; positioning the inserts near an injection molding machine that is used to create the frame; and molding the plastic frame over the inserts. ### Claim 20 (depends on 19) The method of claim 19, wherein the insert is comprised of a non-woven fiber that is less dense, less rigid, and more sound dampening than the plastic in the plastic frame, the method further comprising: selecting the inserts from the table using an arm tool with grippers on retractable needles; and removing the substantially single-layered wheel liner apparatus using the arm tool.