Method and apparatus for assembling a vehicle wheel

Abstract

A method and apparatus for attaching an ornamental overlay to a vehicle wheel by injecting adhesive foam through an aperture of the wheel and into a cavity formed between the wheel and the overlay. A first nest engages the outboard side of the wheel/overlay assembly to seal the inner periphery of the overlay, the valve stem opening of the overlay, the lug bolt receiving holes of the wheel, the pilot aperture of the wheel, and/or the valve stem opening of the wheel. A secondary nest engages the inboard side of the wheel/overlay assembly to seal the wheel apertures and a plurality of turbine openings in the overlay. A nozzle disposed within the secondary nest is adapted to inject the adhesive foam into the cavity through either a gap between the periphery of a wheel aperture and the periphery of a corresponding turbine opening in the overlay, through a straight or angled hole within a spoke, or through a groove within a spoke.

1 - 26 . (canceled)  
   
   
       27 . A composite wheel assembly comprising: 
 a wheel having an outboard surface;    a decorative overlay having a decorative outboard surface and an inboard surface juxtaposed said outboard surface of said wheel, said decorative overlay having a plurality of turbine openings and a plurality of lug nut openings;    an adhesive disposed between said inboard surface of said decorative overlay and said outboard surface of said wheel;    sealing means disposed between said inboard surface of said decorative overlay and said outboard surface of said wheel, said means for sealing adapted to seal any one of said inner periphery of said overlay, outer periphery of said overlay, lug nut openings, valve stem opening and turbine openings whereby said sealing means provides a dam to prevent said adhesive from squeezing out from between said decorative overlay and said wheel, as said decorative overlay is attached to said wheel.    
   
   
       28 . The composite wheel assembly as claimed in  claim 27  wherein said sealing means comprises at least one seal member disposed between said inboard surface of said decorative overlay and said outboard surface of said wheel.  
   
   
       29 . The composite wheel assembly as claimed in  claim 28  wherein said at least one seal member comprises an individual seal member mounted between said decorative overlay and said wheel, said individual seal member sealing the interface of said outer periphery of said decorative overlay to said wheel outboard surface.  
   
   
       30 . The composite wheel assembly as claimed in  claim 28  wherein said at least one seal member comprises an individual seal member mounted between said decorative overlay and said wheel, said individual seal member sealing the interface of said inner periphery of said decorative overlay to said wheel outboard surface.  
   
   
       31 . The composite wheel assembly as claimed in  claim 28  wherein said at least one seal member comprises an individual seal member mounted between said decorative overlay and said wheel, said individual seal member sealing said plurality of turbine openings of said decorative overlay to said wheel outboard surface.  
   
   
       32 . The composite wheel assembly as claimed in  claim 28  wherein said at least one seal member comprises an individual seal member mounted between said decorative overlay and said wheel, said individual seal member sealing said valve stem opening of said decorative overlay to said wheel outboard surface.  
   
   
       33 . The composite wheel assembly as claimed in  claim 28  wherein said at least one seal member comprises an individual seal member mounted between said decorative overlay and said wheel, said individual seal member sealing said plurality of lug nut openings of said decorative overlay to said wheel outboard surface.  
   
   
       34 . The composite wheel assembly as claimed in  claim 28  wherein said at least one seal member comprises an individual seal member mounted between said decorative overlay and said wheel, said individual seal member sealing at least one of said plurality of lug nut openings of said decorative overlay to said wheel outboard surface.  
   
   
       35 . The composite wheel assembly as claimed in  claim 27  wherein said adhesive disposed between said inboard surface of said decorative overlay and said outboard surface of said wheel is selectively disposed.  
   
   
       36 . The composite wheel assembly as claimed in  claim 27  wherein said sealing means further comprises a plurality of individual seal members.  
   
   
       37 . A method for attaching an overlay to a wheel, said method comprising the steps of: 
 providing a wheel having an inboard surface, an outboard surface and a plurality of apertures therethrough, said plurality of apertures each defining an aperture periphery;    providing an overlay having an inboard surface, an outboard surface and a plurality of turbine openings therethrough, said plurality of turbine openings each defining a turbine opening periphery;    attaching said wheel to said overlay thereby providing a wheel/overlay assembly having an inboard surface and an outboard surface, said wheel/overlay assembly defining a cavity between said inboard surface of said overlay and said outboard surface of said wheel;    providing a fixture having a first nest;    providing a foam filling station having at least one second nest disposed therein, said second nest having a nozzle disposed therein;    engaging said first nest with said outboard surface of said wheel/overlay assembly;    engaging said second nest with said inboard surface of said wheel/overlay assembly such that said nozzle is partially radially aligned with one of said plurality of wheel apertures;    injecting a predetermined quantity of adhesive foam through said nozzle, through said one of said plurality of wheel apertures with which said nozzle is partially radially aligned, and into said cavity;    releasing air trapped within said cavity through said vent in said second nest while injecting said predetermined quantity of adhesive foam; and    disengaging said at least one second nest and removing said fixtured wheel/overlay assembly from said foam filling station.    
   
   
       38 . The method as claimed in  claim 37  further comprising the step of applying an adhesive sealant to one of said inboard surface of said overlay and said outboard surface of said wheel before said step of attaching said wheel to said overlay.  
   
   
       39 . The method as claimed in  claim 37  further comprising the step of applying an adhesive sealant to both said inboard surface of said overlay and said outboard surface of said wheel before said step of attaching said wheel to said overlay.  
   
   
       40 . The method as claimed in  claim 37  further comprising the step of applying a preformed gasket to one of said inboard surface of said overlay and said outboard surface of said wheel before said step of attaching said wheel to said overlay.  
   
   
       41 . The method as claimed in  claim 38 , wherein the step of applying an adhesive sealant comprises the step of applying a UV-cure type adhesive sealant.  
   
   
       42 . The method as claimed in  claim 38 , wherein the step of applying an adhesive sealant comprises the step of applying a dual component adhesive sealant.  
   
   
       43 . The method as claimed in  claim 38  further comprising the step of applying a vacuum to said overlay before said step of applying an adhesive sealant.  
   
   
       44 . The method as claimed in  claim 37 , wherein the step of attaching said wheel to said overlay further comprises the steps of: 
 providing an assembly fixture adapted to locate and align said overlay and said wheel;    loading said overlay into said assembly fixture with said outboard surface of said overlay facing said first nest; and    loading said wheel into said assembly fixture such that said outboard surface of said wheel engages said inboard surface of said overlay.    
   
   
       45 . The method as claimed in  claim 37 , wherein said step of attaching said wheel to said overlay further comprises the step of radially aligning said plurality of apertures with said plurality of turbine openings such that a gap is defined between at least one of said aperture periphery and the turbine opening periphery aligned therewith.  
   
   
       46 . The method as claimed in  claim 45 , wherein said step of providing a foam filling station further comprises the step of aligning said nozzle disposed therein such that said nozzle radially aligns with said at least one gap when said second nest engages said wheel/overlay assembly.  
   
   
       47 . The method as claimed in  claim 46 , wherein said step of injecting a predetermined quantity of adhesive further comprises the step of injecting said predetermined quantity of adhesive foam through said at least one gap and into said cavity.  
   
   
       48 . The method as claimed in  claim 37  further comprises the step of heating said wheel/overlay assembly to a predetermined temperature.  
   
   
       49 . A method for permanently attaching an overlay to a wheel, said method comprising the steps of: 
 providing a wheel having an inboard surface, an outboard surface and a plurality of apertures therethrough, said plurality of apertures each defining an aperture periphery;    providing an overlay having an inboard surface, an outboard surface and a plurality of turbine openings therethrough, said plurality of turbine openings each defining a turbine opening periphery;    attaching said wheel to said overlay such that said plurality of apertures radially align with said plurality of turbine openings, said alignment defining a gap between at least one of said aperture periphery and the turbine opening periphery aligned therewith, said step of attaching said wheel to said overlay providing a wheel/overlay assembly having an inboard surface and an outboard surface, said wheel/overlay assembly defining a cavity between said inboard surface of said overlay and said outboard surface of said wheel;    providing a fixture having a first nest;    providing a foam filling station having at least one second nest, said second nest having a nozzle disposed therein such that said nozzle radially aligns with said at least one gap when said second nest engages said wheel/overlay assembly, said second nest further having a vent;    engaging said first nest with said outboard surface of said wheel/overlay assembly;    engaging said second nest with said inboard surface of said wheel/overlay assembly such that said nozzle is radially aligned with said at least one gap;    injecting a predetermined quantity of adhesive foam through said nozzle, through said at least one gap and into said cavity;    releasing air trapped within said cavity through said vent in said second nest while injecting said predetermined quantity of adhesive foam; and    disengaging said at least one second nest and removing said wheel/overlay assembly from said foam filling station.    
   
   
       50 . The method as claimed in  claim 49  further comprising the step of applying an adhesive sealant to one of said inboard surface of said overlay and said outboard surface of said wheel before said step of attaching said wheel to said overlay.  
   
   
       51 . The method as claimed in  claim 49  further comprising the step of applying an adhesive sealant to both said inboard surface of said overlay and said outboard surface of said wheel before said step of attaching said wheel to said overlay.  
   
   
       52 . The method as claimed in  claim 49  further comprising the step of applying a preformed gasket to one of said inboard surface of said overlay and said outboard surface of said wheel before said step of attaching said wheel to said overlay.  
   
   
       53 . The method as claimed in  claim 50 , wherein the step of applying an adhesive sealant comprises the step of applying a UV-cure type adhesive sealant.  
   
   
       54 . The method as claimed in  claim 50 , wherein the step of applying an adhesive sealant comprises the step of applying a dual component adhesive sealant.  
   
   
       55 . The method as claimed in  claim 50  further comprising the step of applying a vacuum to said overlay before said step of applying an adhesive sealant.  
   
   
       56 . The method as claimed in  claim 49 , wherein the step of attaching said wheel to said overlay further comprises the steps of: 
 providing an assembly fixture adapted to locate and align said overlay and said wheel;    loading said overlay into said assembly fixture with said outboard surface of said overlay facing said first nest; and    loading said wheel into said assembly fixture such that said outboard surface of said wheel engages said inboard surface of said overlay.    
   
   
       57 . The method as claimed in  claim 37  further comprising the step of heating said wheel/overlay assembly to a predetermined temperature within the range of 90° to 198° Fahrenheit (32° to 88° C.).  
   
   
       58 . A composite wheel assembly comprising: 
 a wheel having an outboard surface;    a decorative overlay having a decorative outboard surface and an inboard surface juxtaposed said outboard surface of said wheel, said decorative overlay having a plurality of turbine openings and a plurality of lug nut openings;    an adhesive disposed between said inboard surface of said decorative overlay and said outboard surface of said wheel;    sealing means disposed between said inboard surface of said decorative overlay and said outboard surface of said wheel, said means for sealing adapted to seal at least one of said plurality of openings of said overlay wherein said at least one opening is selected from the group consisting of said inner periphery of said overlay, said outer periphery of said overlay, said lug nut openings, said turbine openings and said valve stem opening.