FORM 2
THE PATENTS ACT 1970
(39 of 1970)
&
The Patent Rules, 2003
Complete Specification
(See section 10 and rule 13)
A Steel Wheel for Passenger Cars and Utility Vehicles
Kalyani Maxion Wheels Private Limited
Gate No. 635, Kuruli Village, Chakan, Taluka Khed, Pune 410 501, Maharashtra,
India
Indian company registered under the Indian Companies Act, 1956

Abstract
The designs of the wheels disclosed in prior part do not consider inner wheel mounting pad or surface and hence lead to failure due to stress concentration levels exceeding material tensile strength limits. The invention discloses an outer annular rim connecting flange and a plurality of radial spokes connecting the inner wheel mounting pad to the rim connecting flange. The rim connecting flange extends in an axial direction and defines a side edge surface extending between each pair of adjacent spokes. Pluralities of windows are formed in the wheel disc. Each of the windows has predetermined shape defined by the adjacent spokes and the side edge surface of the rim connecting flange (ring). The rim connecting flange (ring) and the side edge surface are configured such that the window extends to an outermost periphery of the wheel disc. A wheel disc having a correlation between mounting holes and large windows in a way to generate a minimal stresses in the adjoining area leading to high strength withstanding the impact and cyclic load exerted during typical Indian road conditions is disclosed.
Representative Figure: Figure 1

Field of the invention
The present invention relates to vehicle wheel. In particular the invention relates
to a steel wheels for Passenger Cars and Utility Vehicle.
Background of the Invention
This invention relates in general to passenger cars and utility vehicles (hence after
called PC & UV) wheels and in particular to an improved fabricated vehicle
wheel.
A conventional fabricated vehicle wheel is typically of a two piece construction and includes an inner disc and an outer “full” rim. The disc can be fabricated from steel, aluminium or other alloys, and includes an inner annular wheel mounting portion and an outer annular portion. The wheel mounting portion defines an inboard mounting surface and includes a center pilot or hub hole, and a plurality of lug receiving holes formed there through for mounting the wheel to an axle of the vehicle.
The rim is fabricated from steel, aluminium, or other alloys and includes an inboard tire bead seat retaining flange, an inboard tire bead seat, an axially extending well, an outboard tire bead seat, and an outboard tire bead seat retaining flange. In some instances, a three-piece wheel construction having a mounting cup secured to the disc is used. In both types of constructions, the outer annular portion of the disc is typically secured to the rim by welding.

Summary of Invention
The designs of the wheels disclosed in prior part do not consider inner wheel mounting pad or surface and hence lead to failure due to stress concentration levels exceeding material tensile strength limits.
An outer annular rim connecting flange and a plurality of radial spokes connecting the inner wheel mounting pad to the rim connecting flange.
The rim connecting flange extends in an axial direction and defines a side edge surface extending between each pair of adjacent spokes.
Pluralities of windows are formed in the wheel disc. Each of the windows has predetermined shape defined by the adjacent spokes and the side edge surface of the rim connecting flange(ring). The rim connecting flange(ring) and the side edge surface are configured such that the window extends to an outermost periphery of the wheel disc.
A wheel disc having a correlation between mounting holes and large windows in a way to generate a minimal stresses in the adjoining area leading to high strength withstanding the impact and cyclic load exerted during typical Indian road condition

A wheel disc having the predetermined shape and variation in thickness of in thickness of spokes in drawing processare controlled all along the shape of the spoke which will withstand the excess loading application on the wheel.
A fabricated vehicle wheel rim and disc comprising of the diameters of adjoining area of rim inner area and disc outer& inner area which area machined in such a way to generate a fit suitable for axial as well as radial and circumferential loading exerted during vehicle operation.
A fabricated vehicle wheel disc having predetermined shape, thickness of the material and all the metallurgical and chemical structure of the material in a way to provide least weight and high life in fatigue application for an Indian condition.
A fabricated wheel rim comprising of the design and quality parameters of the each component of wheel rim with respect the rotational axis of the wheel rim including the bead seat area, mounting pad area, the concentricity of bolt holes and center bore and also the positioning of bolt holes with respect to the bore, in a way to leading to higher tyre life, balanced rotating condition, facilitating use of lesser balance weights while balancing the tyre and wheel dynamically.
Objects of the Invention
The main object of the invention is to provide improved styled wheel for Indian
application.

Further object of the invention is to provide the wheel which will have visual look of an aluminum alloy wheel when fitted with the plastic cap.
Another object of the invention is to provide the wheel which will assist in applicability to use lighter axles thereby assisting to reduce overall weight of the vehicle.
Yet another object of the wheel is to induce applicability of using plastic cap which can be mounted on spokes which are at the adjoining area from central hub to outer ring. This facilitates prevention of cap damages during mounting and dismounted (in case the cap is mounted on stud holes), cap rotation & resulting into damage of air inflation valves (in case the cap is mounted on the inner periphery of outer rim) while vehicle is running and also assists the use of logo at the centre of cap.
Yet another object of the wheel is to induce cold working strength in the proximity judiciously optimized with the available area around the stud hole.
Yet another object of the invention is to provide the wheel which will assist in braking performance in view of typical Indian traffic scenario wherein one needs to apply frequent braking to commute safely on the road.

Yet another object of the invention is to provide judicious combination of improved bolt hole region stress enhancement geometry and material having corresponding safe tensile strength so as to sustain / cater to acute load conditions on the vehicle (and in turn wheel).
Yet another object of the invention is to provide disc material of enhanced tensile strength.
Yet another object of the invention is to modify geometry around the said stud holes in terms of plastic flow of the volume of material to enhance strength and cater to stresses due to acute loading.
Brief Description Of The Drawings
Figure 1 is a view of a first embodiment of a fabricated vehicle wheel in
accordance with the present invention.
Figure 2 is a view of the wheel disc illustrated in Figure1
Figure 3 is a sectional view of a portion of the vehicle wheel taken along line 3 -3
of Figure 1 except showing solid spokes.
Figure 4 is an enlarged view of a portion of the vehicle wheel illustrated in Figure
3 showing an alternate method for joining the wheel disc to the wheel rim.
Figure 5 is a view of a second embodiment of a fabricated vehicle wheel in
accordance with the present invention.
Figure 6 is a view of the wheel disc illustrated in Figure 5

Figure 7 is a view of Figure 3 with additional steel sheet glued on the face
Description Of The Preferred Embodiments
Referring now to FIGS.1-3 there is illustrated a first embodiment of a fabricated vehicle wheel, indicated generally at 410 produced in accordance with the present invention. The vehicle wheel 410 produced according to this invention is illustrated as being a fabricated drop center or well attached vehicle wheel. The fabricated bead drop center vehicle wheel 410 includes a full wheel rim 420 and an inner wheel disc 440 which are constructed an joined together in accordance with the present invention.
The wheel rim 420 is a fabricated rim formed from a suitable material such as for example, steel, aluminium or alloys thereof magnesium or titanium. As shown in FIG 25 the wheel rim 420 includes an inboard tire bead seat retaining flange 422, an inboard tire bead seat 424, a generally axially extending well 426 an outboard tire bead seat 428 and an outboard tire bead seat retaining flange 430. The well 426 includes an inner surface 426A.
The wheel disc 440 is fabricated or otherwise formed from a suitable low carbon steel or high strength low alloy material such as for example, steel, aluminium or alloy thereof, steel, magnesium or titanium. The wheel disc 440 defines a wheel axis X and includes a generally centrally located wheel mounting surface or portion 442, a plurality of outwardly extending spokes 444 and an outer band or

flange 447. In the illustrated embodiment the disc 440 includes five of such spokes 444 which are shown as being formed integral with the wheel mounting surface 442 and the outer flange 447. Alternatively, the number and/or the construction of the spokes 444 can be other than illustrated if so desired. For example the vehicle wheel 410 can include less than five spokes 444 or more than five spokes 444. Also the spokes 444 and the outer flange 447 can be formed integral with one another but separate from the wheel mounting surface 442 of the disc 440 and joined thereto by a suitable method.
The wheel mounting surface 442 is provided with a centrally located pilot aperture 442A and a plurality of lug bolt receiving holes 442 B circumferentially spaced around the pilot aperture 442A. In the illustrated embodiment, the wheel mounting surface 442 includes four of such lug bolt receiving holes 442B which are preferably provided in the wheel mounting surface 442 in line with a respective one of each of the spokes 444. Alternatively, the number and/or the location of the lug bolt receiving holes 442B can be other than illustrated if so desired. The lug bolt receiving holes than illustrated if so desired. The lug bolt receiving holes 442B receive lug bolts (not shown) and nuts (not shown) for securing the vehicle wheel 410 on an axle (not shown) of a vehicle.
The mounting surface 442 further includes a plurality of strengthening ribs 442C provided therein. In the illustrated embodiment a rib 442C is located between each pair of lug bolt receiving holes 442B. each of the ribs 442C is defined by a raised

or embossed area which extends outwardly from or above the mounting surface 442. The ribs 442C are operative to strengthen the mounting surface 442 to keep it from flexing during vehicle operation thereby improving the fatigue life of the associated vehicle wheel. Alternatively the spacing location, number and / or configuration of the ribs 442C can be other than illustrated and described if so desired.
The wheel disc 440 may also include one or more spoke protrusions with small opening 446 formed in one or more of each of the spokes 444. In the illustrated embodiment of FIGS.1 and 2, one of such spoke protrusions with small opening 446 is provided in each of the spokes 444. Alternatively, the number and/or the location of the spoke protrusions with small opening 446 can be other than illustrated if so desired. Also as shown in FIG 3 the spoke 44 can be formed as a solid spoke not having the spoke protrusions with small opening 446 formed therein. As shown in this embodiment, the outer flange 447 extends solely in a generally axial direction, defies an annular mounting flange and includes an outer surface 447 A and a side edge surface 447B (shown in FIG 2), extending between adjacent pairs of spokes 444. As shown in FIG. 3 the side edge surface 447B faces in a generally axial outboard direction.
The assemble the vehicle wheel 410 in the illustrated embodiment, the wheel rim 420 and the wheel disc 440 are located relative to one another in a predetermined position. In particular the outer surface 447A of the mounting flange 447 is

positioned adjacent the inner surface 426A of the well 426 of the wheel rim 420 and a weld 450 (shown in FIG.3) is applied to join the wheel disc 440 and the wheel rim 420 together to produce the fabricated well attached vehicle wheel. As can be seen in FIG.1 due to the construction of the wheel disc 440 the resultant wheel 410 has a relatively large vent window 410A formed therein between each pair of the spokes 444. Also while the wheel disc 440 is shown for use in constructing a fabricated well attached vehicle wheel, the wheel disc 440 could be used to produce other types of fabricated vehicle wheels. For example the wheel disc 440 could be used to produce a fabricated bead seat attached vehicle wheel or a fabricated full face vehicle wheel. Also as shown in FIG.2 each spoke 444 defines a radial line R intersecting the wheel axis X and each spoke 444 is preferably symmetrical with respect to the radial line R.
Alternatively, as shown in FIG.4 the wheel disc 440 and the wheel rim 420 can be secured together by using an adhesive 460 and a plurality of suitable fasteners 462 (only one of such fasteners 462 being illustrated in FIG.4). Preferably, a suitable adhesive 460 is first applied to the outer surface 447A of the mounting flange 447. A suitable adhesive 460 is a one part epoxy available under the name BETAMATE® 4601, manufactured by Down Chemical Company of Midland. Mich. Alternatively the type and/or the application of the adhesive 460 can be other than illustrated and described if so desired. For example, the adhesive 460 can be first applied to the inner surface 426A of the well 426 of the wheel rim 420.

Next, the wheel rim 420 and the wheel disc 440 are located relative to one another in a predetermined position. In this position, the well inner surface 426A is disposed adjacent the mounting flange outer surface 447A. While in this position, a plurality of wheel rim holes 466 and mounting flange holes 468 are preferably formed in the wheel rim 420 and wheel disc 440, respectively at the same time by a suitable method, such as for example, by piercing, drilling or laser cutting. Forming the holes 466 and 468 in this manner ensures that the holes are in proper alignment. Next a suitable fastener 462 is installed in each of the aligned holes 466 and 468 to thereby join the wheel rim 420 and the wheel disc 440 together. Alternatively, the holes 466 and 468 can be separately provided in one or both of the wheel rim 420 and the wheel disc 440 prior to assembly if so desired. In the illustrated embodiment, the fastener 462 is a rivet and includes a generally round body 462A, an outer or head portion 462B and an inner portion 462C. Also the holes 466 and 468 are preferably countersunk holes so that when the rivet 462 is installed no portion of the rivet 462 protrudes outside of a well outer surface 426B and a mounting flange inner surface 447B of the wheel rim 420 and the wheel disc 440, respectively. Alternatively the type, configuration location and/or the number of fasteners 462 that are used can be other than illustrated if desired.
Referring now to FIGS. 5 and 6, there is illustrated a second embodiment of a fabricated vehicle wheel, indicated generally at 510, produced in accordance with the present invention. The vehicle wheel 410 produced according to this invention is illustrated as being a fabricated drop center vehicle wheel. In this embodiment

spokes 544 of a wheel disc 540 are inverted or reversed compared to the spokes
444 of the wheel disc 440 of the vehicle wheel 410 illustrated in FIGS1-3. Thus,
in this embodiment, the spokes 544 of the wheel disc 540 project outwardly as
opposed to the spokes 444 of the wheel disc 440 which project inwardly.
In accordance with the provisions of the patent statutes the principle and mode of
operation of this invention have been described and illustrated in its preferred
embodiments.

We claim:
1. A steel wheel for passenger cars and utility vehicles characterized in that it comprises:
- a wheel rim including an inboard tire bead seat retaining flange, an inner tire bead seat, a well, an outer tire bead seat, an outboard tire bead seat retaining flange;
- a wheel disc joined to said wheel rim and defining a wheel axis, said wheel disc including an inner wheel mounting pad, an outer annular rim connecting flange, said rim connecting flange extending solely in an axial direction, said rim connecting flange defining a side edge surface extending between each pair of adjacent spokes;
- a separate window formed in said wheel disc between each pair of adjacent spokes, each window having a predetermined shape defined by said adjacent spokes and said side edge surface of said rim connecting flange such that each window extends to an outermost periphery of said wheel disc;
- a wheel disc having pre-determined correlation between wheel mounting stud holes with adjoining spokes and the separate large windows; and
- a wheel disc having a one or more protrusions on one or more spokes of the disc along with a small hole, enabling its applicability to use the wheel cap or any other wheel cover;

2. The fabricated vehicle wheel according to claim 1 wherein each of said spokes defines a radial line intersecting said wheel axis each of said spokes is symmetrical with respect to said radial line.
3. The fabricated vehicle wheel according to claim 2 further including a separate lug bolt hole formed in said inner wheel mounting pad between each pair of adjacent spokes, each of said lug bolt holes located at a predetermined relation with respect to the radial line of each of said spokes.
4. The fabricated vehicle wheel according to claim 3 wherein said inner wheel mounting pad includes a strengthening rib provided therein which is located between each pair of adjacent lug bolt holes.
5. The fabricated vehicle wheel according to claim 1 wherein said wheel disc and said wheel rim are joined together by welding.
6. The fabricated vehicle wheel according to claim 1 wherein said wheel rim includes a plurality of holes formed therein, said wheel disc includes a plurality of holes formed therein, and wherein said wheel disc and said wheel rim are joined together by a plurality of fasteners extending through said holes of said wheel rim and said holes of said wheel disc and by an adhesive disposed between adjacent surfaces of said wheel rim and said wheel disc.

7. The fabricated vehicle wheel according to claim 1 wherein said spokes are formed integral with said inner wheel mounting pad and said rim connecting flange.
8. The fabricated vehicle wheel according to claim 1 wherein each of said spokes includes a separate opening formed therein.
9. The fabricated vehicle wheel according to claim 1 wherein an additional steel / non-ferrous sheet is glued on the front face of the wheel with an adhesive.
10. A fabricated vehicle wheel comprising :

- a wheel rim including an inboard tire bead seat retaining flange, an inner tire bead seat, a well, an outer tire bead seat, and an outboard tire bead seat retaining flange;
- a wheel disc joined to said wheel rim an defining a wheel axis, said wheel disc including an inner wheel mounting pad, an outer annular rim connecting flange and a plurality of radial spokes connecting said inner wheel mounting pad to said rim connecting flange, said rim connecting flange extending in an axial direction and including a side edge surface extending between each pair of adjacent spokes and facing in a generally axial outboard direction; and

- a separate window formed in said wheel disc between each pair of adjacent spokes, each window having a predetermined shape defined by said adjacent spokes and said side edge surface of said rim connecting flange such that each window extends to an outermost periphery of said wheel disc;
wherein each of said spokes defines a radial line intersecting said wheel axis and each of said spokes is symmetrical with respect to said radial line, and wherein a separate lug bolt hole is formed in said inner wheel mounting pad between each pair of adjacent spokes, each of said lug bolt holes located along said radial line of each of said spokes.
11. The fabricated vehicle wheel according to claim 9 wherein each of said spokes includes a separate opening formed therein.