TECHNICAL FIELD

The present invention relates to the field of wheels, and more particularly, to wheel assemblies for a vehicle and related methods.

BACKGROUND

A typical wheel may include a rim and tire surrounding the rim. The tire transfers a load of a vehicle from the axle through the wheel to the ground. Tires, for example, those found on most vehicles are pneumatic tires. In other words, a typical tire is pneumatically inflated, for example, with air or other gas, such as nitrogen. More particularly, air is injected into the space between the rim and the inside of the tire to inflate it.

During operation, being pneumatically inflated, a tire absorbs the forces as the vehicle travels over the road surface. The tire and associated inflation pressure may be selected to absorb the above-noted forces while reducing any deformation. However, in many instances, excessive forces placed on the tire may cause the tire and/or rim to deform, puncture, or blowout. Typical forces also cause tread wear of the tire, while excessive forces may also cause rapid tread wear that may lead to a shortened lifespan of the tire and decreased structural integrity of the wheel.

To address the shortcomings of pneumatic-based wheels, non-pneumatic wheels have been developed. By non-pneumatic, it is meant that air or other gas is not injected to inflate an interior volume of a tire. One approach to a non-pneumatic wheel uses mechanical springs. For example, U.S. Pat. No. 911,975 to Gustafson discloses a spring wheel. Secondary spokes are arranged in pairs between pairs of main spokes and the members of each of the secondary spokes therefore pass upon opposite sides of a corresponding pair of intersecting braces. Each of the secondary spokes includes a pair of telescoping members that are pivotally connected at its outer end to ears formed on the hub and extends at its opposite end into a corresponding member.

U.S. Pat. No. 1,601,518 to Weston discloses a resilient wheel that includes radial arms. Connection between a hub and rim members may be provided by pivot pins in outer ends of these arms that have links journaled thereon. The links are pivotally articulated with bent levers, which are in turn pivoted on bracket arms that extend inwardly from the part-circular plates, which are mounted on an inner periphery of a tire holding rim.

Another approach includes a disc between a wheel hub and outer rim. For example, U.S. Pat. No. 1,808,886 to Courtney also discloses a disc or sidewall between a wheel hub and a rim. The disc is engaged by studs that project from the wheel hub and extends from an outer flange obliquely to the wheel hub. The disc assists the wheel tire and rim by resisting any tendency to become displayed laterally as a result of stresses occurring while the wheel is turning.

U.S. Pat. No. 1,979,935 to Henap discloses a hydraulic spoke wheel. Each of the hydraulic spokes include telescoping sections in the form of an outer section and an inner section. The outer section has the stud projecting from one end. The inner section extends from the outer section and is equipped at its extended end with the stem.

U.S. Pat. No. 6,041,838 to Al-Sabah discloses a wheel that includes spokes positioned in a spaced apart relation to each other. Each of the spokes has a first end connected to a rim and a second end connected to a plate member tip of a hub plate member in an offset position from the respective radial axis thereof. The offset position of each of the spokes is further defined by each of the spokes being connected to a respective one of the plate member tips at a predetermined angle (e.g., less than 90-degrees) from the radial axis thereof and defining an operative offset spoke axis, which intersects the radial axis of the plate member tips at the predetermined angle.

U.S. Pat. No. 6,698,480 to Cornellier discloses shock absorbing spokes each having a central cylindrical tube. Each tube has an interior cap having an aperture and an exterior cap having an aperture. Each spoke has an interior piston, a rod with an aperture and a pin. The pin pivotably couples one of the spokes to the hub. Each spoke has an exterior piston, a rod with an aperture and a pin. The pin pivotably couples one of the spokes to the rim assembly. The interior pistons and exterior pistons divide the space within each tube into an interior chamber, an exterior chamber, and a central chamber.

Despite advances in pneumatic tire wheels, and non-pneumatic tire wheels, there is still a need for improvements in wheel technology, particularly, for large construction vehicles, or mining vehicles, for example. The expense of wheel replacement, and the downtime experienced during wheel replacement may add significant expenses to the construction or mining projects.

SUMMARY

A wheel assembly to be coupled to a hub of a vehicle may include a plurality of arcuate inner rim assemblies removably coupled together to define a circular inner rim to be coupled to the hub of the vehicle. Each arcuate inner rim assembly may include an arcuate inner rim segment, and an arcuate inner ring segment extending radially outward from the arcuate inner rim segment. The wheel assembly may also include a plurality of arcuate outer rim assemblies removably coupled together to define a circular outer rim. Each arcuate outer rim assembly may include an arcuate outer rim segment, and an arcuate outer ring segment extending radially inward from the arcuate outer rim segment. The wheel assembly may also include a plurality of gas springs operatively coupled between the circular inner rim and the circular outer rim to provide a gas suspension for relative movement therebetween.

Each of the plurality of arcuate inner rim assemblies may include a respective inner flange at each end of the arcuate inner rim segment and the arcuate inner ring segment for coupling adjacent ones of the plurality of arcuate inner rim assemblies in end-to-end relation. Each inner flange may have a plurality of inner flange fastener receiving passageways therein, for example, and the wheel assembly may include a plurality of inner flange fasteners for coupling adjacent arcuate inner rim assemblies via the plurality of inner flange fastener receiving passageways.

Each of the plurality of arcuate outer rim assemblies may include a respective outer flange at each end of the arcuate outer rim segment and the arcuate outer ring segment for coupling adjacent ones of the plurality of arcuate outer rim assemblies in end-to-end relation. Each outer flange may have a plurality of outer flange fastener receiving passageways therein, for example, and the wheel assembly may include a plurality of outer flange fasteners for coupling adjacent arcuate outer rim assemblies via the plurality of outer flange fastener receiving passageways.

The plurality of arcuate outer ring segments and arcuate inner ring segments may define a gap therebetween to provide a mechanical stop to limit relative movement, for example. The plurality of arcuate inner rim assemblies may include a number of arcuate inner rim assemblies from 2 to 4, for example.

The plurality of arcuate outer rim assemblies may include a number of arcuate outer rim assemblies from 2 to 4. The plurality of gas springs may be arranged in pairs on opposite sides of the plurality of arcuate outer ring segments. The plurality of gas springs may diverge outwardly from the plurality of arcuate inner rim segments to the plurality of arcuate outer rim segments, for example.

A method aspect is directed to a method of assembling a wheel assembly to be coupled to a hub of a vehicle. The method may include coupling together a plurality of arcuate inner rim assemblies to define a circular inner rim to be coupled to the hub of the vehicle. Each arcuate inner rim assembly may include an arcuate inner rim segment, and an arcuate inner ring segment extending radially outward from the arcuate inner rim segment. The method may also include coupling together a plurality of arcuate outer rim assemblies to define a circular outer rim. Each arcuate outer rim assembly may include an arcuate outer rim segment, and an arcuate outer ring segment extending radially inward from the arcuate outer rim segment. The method may also include operatively coupling a plurality of gas springs between the circular inner rim and the circular outer rim to provide a gas suspension for relative movement therebetween.

