Decorative capped wheel nut or bolt assembly and method

Abstract

A decorative cap and wheel nut or bolt insert assembly, and a method of assembling them. The insert is coated and/or plated and includes a hex-shaped section and a section having a circular cylindrical outer surface. A cap includes a hex cross-section segment and a circular cylindrical cross-section segment. The hex cross-section segment of the cap slips easily over the hex section of the insert while the circular cylindrical cross-section segment has a smaller ID than the OD of the circular cylindrical insert section. The cap is formed of sheet material which is both plastically and elastically deformable. When pressed onto the insert, the cap deforms both plastically and elastically. An interference fit is formed between them by radial plastic deformation of the cap.

1 ) A wheel fastener comprising: 
 (a) a bolt body that includes a flange, a head, a base, and an axis;    (b) a cap that is fabricated from a stainless steel and generally shaped according to the head the bolt body;    (c) a generally spherically shaped section that is located at the second end of the head and adapted to seat in a wheel rim aperture;    (d) the head of the bolt body is provided with a first end and a second end and includes a flange that extends radially from the axis;    (e) the first end of the head is configured to engage, at least in part, the cap so that the cap is retained on the head of the bolt body;    (f) the cap is provided with a flared lip that extends over the flange of the head of the bolt body and generally terminates, at least in part, at a generally cylindrical surface;    (g) the generally cylindrical surface axially separates the cap and the generally spherically shaped section and is located adjacent to the generally spherically shaped section;    (h) the head of the bolt body is provided with a plurality of wall segments that are oriented in a generally hexagonal manner;    (i) the base of the bolt body is threaded and extends axially from the generally spherically shaped section of the head; and    (j) the head of the bolt body is free of welding attachment to the cap.    
   
   
       2 ) The wheel fastener of  claim 1  wherein: 
 (a) the bolt body includes an external surface that is provided with a coating; and    (b) the coating is approximately 0.001 inches thick.    
   
   
       3 ) The wheel fastener of  claim 1  wherein the generally cylindrical surface is provided with an axial length that is less than 0.150 inches.  
   
   
       4 ) The wheel fastener of  claim 1  wherein: 
 (a) the bolt body includes an external surface that is provided with a coating; and    (b) the coating is substantially chromium free.    
   
   
       5 ) The wheel fastener of  claim 1  wherein the cap has a thickness of 0.018 to 0.020 inches.  
   
   
       6 ) The wheel fastener comprising: 
 (a) a bolt body that includes an axis, a head, and a base that is, at least in part, threaded;    (b) the head of the bolt body is provided with a flange, a first end, and a second end;    (c) the flange, at least in part, retains a cap on the head and is provided with a generally cylindrical surface;    (d) the first end of the head is provided with a plurality of wall segments that are oriented in a generally hexagonal manner;    (e) the second end of the bolt extends axially from the base and radially from the axis of the bolt body;    (f) the second end of the head is adapted to seat in a wheel rim aperture and terminates at the generally cylindrical surface;    (g) the cap is fabricated from a stainless steel and generally shaped according to the first end of the head of the bolt body;    (h) the cap includes a flared end that extends around at least a portion of the flange and terminates so that the generally cylindrical surface of the head axially separates the cap and the second end of the head of the bolt body; and    (i) the head of the bolt body is free of welding attachment to the cap.    
   
   
       7 ) The wheel fastener of  claim 6  wherein: 
 (a) the bolt body includes an external surface that is provided with a coating; and    (b) the coating is approximately 0.001 inches thick.    
   
   
       8 ) The wheel fastener of  claim 6  wherein the generally cylindrical surface is provided with an axial length that is less than 0.150 inches.  
   
   
       9 ) The wheel fastener of  claim 6  wherein: 
 (a) the bolt body includes an external surface that is provided with a coating; and    (b) the coating is substantially chromium free.    
   
   
       10 ) The wheel fastener of  claim 6  wherein: 
 (a) the flared end of the cap is provided with an inner diameter;    (b) the flange of the bolt body is provided with an outer diameter; and    (c) the outer diameter of the flange is at least 0.020 greater than the inner diameter of the flared end of the cap.    
   
   
       11 ) The wheel fastener of  claim 6  wherein the cap has a thickness of 0.018 to 0.020 inches.