Abstract: A light assembly including two light sources through a single inner lens made of two separate materials includes a first light source that is operable to emit light for a position light function of the vehicle, and a second light source that is operable to emit light for a Daytime Running Light function of the vehicle. The light assembly further includes an inner lens having a first portion and a second portion. The first portion is formed from a mixture of polymethyl methacrylate and polyetheresteramide, and is operable to receive light from the first light source adjacent a light receiving edge of the first portion and reflect the light to provide the position light function. The second portion of the inner lens is formed from polymethyl methacrylate without polyetheresteramide, and is operable to receive light from the second light source and direct the light to provide the DRL function.

Abstract: A light assembly including two light sources through a single inner lens made of two separate materials includes a first light source that is operable to emit light for a position light function of the vehicle, and a second light source that is operable to emit light for a Daytime Running Light function of the vehicle. The light assembly further includes an inner lens having a first portion and a second portion. The first portion is formed from a mixture of polymethyl methacrylate and polyetheresteramide, and is operable to receive light from the first light source adjacent a light receiving edge of the first portion and reflect the light to provide the position light function. The second portion of the inner lens is formed from polymethyl methacrylate without polyetheresteramide, and is operable to receive light from the second light source and direct the light to provide the DRL function.

Abstract: In one aspect, an elastically averaged alignment system is provided. The system includes a first component having a plurality of opposed alignment members, the plurality of opposed alignment members defining a channel therebetween, and a second component configured for insertion into the channel between the plurality of opposed alignment members. At least one of the plurality of opposed alignment members and the second component is an elastically deformable material such that when the second component is inserted into the channel, at least one of the plurality of opposed alignment members and the second component elastically deform to an elastically averaged final configuration to facilitate aligning the first component and the second component in a desired orientation.

Abstract: A method of forming an emblem assembly configured for attachment to a vehicle includes positioning a mask adjacent and in contact with a second element so that the mask covers only a selected portion of the second element and does not cover an exposed portion of the second element. The method includes vacuum metalizing a first coating onto only the exposed portion, wherein the first coating has a distal edge surface abutting the mask, and, after vacuum metalizing, removing the mask from the second element to uncover the selected portion. The method includes depositing a back coating onto only the first coating and the selected portion to thereby wrap the back coating around the distal edge surface, and, after depositing, inserting the second element into a first element configured for attachment to the vehicle so that the first coating does not contact the first element to form the assembly.

Abstract: A display emblem may comprise a metallized layer, a decoration layer, and at least one moisture impermeable layer.

Abstract: A method of forming an emblem assembly configured for attachment to a vehicle includes positioning a mask adjacent and in contact with a second element so that the mask covers only a selected portion of the second element and does not cover an exposed portion of the second element. The method includes vacuum metalizing a first coating onto only the exposed portion, wherein the first coating has a distal edge surface abutting the mask, and, after vacuum metalizing, removing the mask from the second element to uncover the selected portion. The method includes depositing a back coating onto only the first coating and the selected portion to thereby wrap the back coating around the distal edge surface, and, after depositing, inserting the second element into a first element configured for attachment to the vehicle so that the first coating does not contact the first element to form the assembly.

Abstract: A method of forming an article attachable to an exterior surface of a vehicle includes heating a thermoplastic system to form a workpiece. The thermoplastic system includes a substrate having an end surface, and a film disposed on the substrate and having a distal surface adjoining the end surface. The workpiece has a first surface adjoining the distal surface to define a distal edge, and a second surface spaced opposite the first surface and adjoining the end surface to define a proximal edge between the second and end surfaces. The method includes disposing the workpiece between a mold surface and a pressure surface. After disposing, the method includes conforming the first surface to one of the pressure and mold surfaces to form a preform, and depositing an injection-moldable polymer onto the preform to form a protective layer thereon that contacts and covers the distal surface. An article is also disclosed.

Abstract: A method of forming an article attachable to an exterior surface of a vehicle includes heating a thermoplastic system to form a preform. The preform has a first surface having an initial distinctness of image and an initial gloss, and a second surface spaced opposite from the first. The method also includes disposing the preform between a mold surface and a pressure surface spaced apart from the mold surface so that the first surface faces the mold surface, and the second surface faces the pressure surface. Further, the first surface and the mold surface define a first cavity therebetween, and the second surface and the pressure surface define a second cavity therebetween. After disposing, the method includes conforming the first surface to the mold surface to thereby form the article, wherein the article has the initial distinctness of image and the initial gloss.

Abstract: A thermoforming methodology for laminated thermoplastic sheets which preserves the class “A” finish and high gloss thereof. In a thermoforming process including heating followed by vacuum and opposing air pressure application, and then followed by application of chilled compressed air, control of spherulite formation using any of: addition of a nucleating agent to the paint film, using the chilled compressed air at a temperature of substantially about 32° F., heating to no more than about 311° F., selecting a paint film having a high melting point temperature, and selecting a paint film that is non-crystalline.

Abstract: A thermoforming methodology for laminated thermoplastic sheets which preserves the class “A” finish and high gloss thereof. A thermoformer has a vacuum box component which includes a mold, and a pressure box component which is selectively sealable in relation to the vacuum box component. A heated laminated thermoplastic sheet is placed in the thermoformer, the class “A” side thereof facing away from the mold, and the thermoformer sealed. Vacuum is applied to the vacuum box component and simultaneously air pressure is applied to the pressure box component, including application of chilled compressed air, resulting in forming of the sheet on the mold and controlled cooling of the sheet which preserves its class “A” finish and high gloss.

Abstract: A thermoforming methodology for laminated thermoplastic sheets which preserves the class “A” finish and high gloss thereof. In a thermoforming process including heating followed by vacuum and opposing air pressure application, and then followed by application of chilled compressed air, control of spherulite formation using any of: addition of a nucleating agent to the paint film, using the chilled compressed air at a temperature of substantially about 32° F., heating to no more than about 311° F., selecting a paint film having a high melting point temperature, and selecting a paint film that is non-crystalline.

Abstract: A thermoforming methodology for laminated thermoplastic sheets which preserves the class “A” finish and high gloss thereof. A thermoformer has a vacuum box component which includes a mold, and a pressure box component which is selectively sealable in relation to the vacuum box component. A heated laminated thermoplastic sheet is placed in the thermoformer, the class “A” side thereof facing away from the mold, and the thermoformer sealed. Vacuum is applied to the vacuum box component and simultaneously air pressure is applied to the pressure box component, including application of chilled compressed air, resulting in forming of the sheet on the mold and controlled cooling of the sheet which preserves its class “A” finish and high gloss.