Abstract: A decorative metal finish for a part with a non-conductive surface where the non-conductive surface is lightly roughened to improve its adherence capabilities. A thin metal layer is electrolessly deposited on the lightly roughened surface to provide a bright durable metal finish on the non-conductive surface. An translucent finish is deposited over the thin metal layer to provide protection for the metal finish.

Abstract: An improved process for permanently attaching an overlay to a wheel disc, wherein the overlay is aligned and spaced apart from the wheel disc. A mold is created by a combination of the overlay, wheel disc and localized nests that engage at predetermined times during foam filling to close the mold. The mold is adequately sealed so that there is no foam leakage as the foam expands to fill the mold and, therefore, no final trimming of excess foam is required. The improved process is capable of accommodating a wheel having turbine openings therein.

Abstract: A vehicle wheel and overlay assembly having an overlay that extends radially outward to cover substantially the entire outboard surface of the wheel, without wrapping around the periphery of the wheel. The assembly includes a wheel having a flangeless or minimum functional flange height rim flange or alternatively a truncated rim flange that terminates in a flange lip having a radially outermost edge. An overlay is attached to and closely contours the wheel outboard surface and radially terminates in a peripheral flange that has a peripheral lip with a radially outermost edge that is aligned with the outermost edge of the wheel flange lip within a predetermined circumferential margin so that the peripheral flange covers at least a portion of the wheel flange lip. This configuration gives the visible impression that this is a one-piece wheel, where the outboard surface of the overlay appears to be the outboard surface of the wheel, and not a separate component.

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.

Abstract: A wheel and overlay assembly employing an overlay configured to more fully control the aesthetic appearance of the assembly. The wheel and overlay assembly employs an overlay that more completely establishes the decorative appearance of the assembly, thereby enabling the use of a standardized wheel whose design and construction considerations are based almost solely on the structural requirements of the assembly. As such, the overlay is adapted to enable the functions of structural integrity and outward appearance of the assembly to be addressed separately, resulting in a more fully integrated appearance in which the two-component construction of the assembly is fully concealed, such that a substantial reduction in manufacturing costs is achieved due to the reduced functional demands on the wheel.

Abstract: An improved process for permanently attaching an overlay to a wheel disc, wherein the overlay is aligned and spaced apart from the wheel disc. A mold is created by a combination of the overlay, wheel disc and localized nests that engage at predetermined times during foam filling to close the mold. The mold is adequately sealed so that there is no foam leakage as the foam expands to fill the mold and, therefore, no final trimming of excess foam is required. The improved process is capable of accommodating a wheel having turbine openings therein.

Abstract: An exhaust tip for attachment to a tailpipe that includes a thermoset heat shield at least partially surrounding and fastened to the tailpipe, and a thermoplastic decorative cover at least partially surrounding and fastened to the thermoset heat shield. The thermoset heat shield insulates the thermoplastic decorative cover from thermal effects of the tailpipe and spaces the thermoplastic decorative cover a predetermined distance away from the tailpipe.

Abstract: An ornamental wheel cover integrally retained on the lug nuts of a vehicle wheel that provides positive positioning of the cover to the lug nuts. The cover is provided with a number of elongated tubular extensions axially projecting therefrom that are each partially slotted to provide a plurality of cantilevered fingers. Each finger has an undercut groove that positively positions the cover to the lug nuts of the wheel. When the cover is attached to the wheel, the elongated tubular extensions are aligned with the lug nuts and the cover is moved axially inwardly of the wheel so that the cantilevered fingers separate slightly as they pass over the flange of the lug nut. The wheel cover further includes a wire band retainer to bias the innermost cantilevered fingers into continual engagement with the lug nuts, even during temperatures that would otherwise cause the plastic to distort due to heat creep.

Abstract: An apparatus and method for constructing a wheel assembly by adhesively bonding a wheel cover to a wheel using a bead of foamed-in-place adhesive. As the wheel and wheel cover are assembled together, the bead of foamed-in-place adhesive is compressed between the wheel cover and the wheel, and thereby spreads out therebetween. The method results in a more complete volumetric fill of adhesive between the wheel cover and wheel, and results in a faster cure time of adhesive when compared to the prior art, thereby enabling a reduction in manufacturing cycle time and work-in-process inventory.

Abstract: A body subassembly for a vehicle that is designed to be mounted substantially flush with the surrounding vehicle body panels and an impact-absorbing bumper, and that is capable of deflecting with the stroke of the impact-absorbing bumper during impact. The body subassembly is preferably formed with at least one deformable resilient deflection member selectively located between an exterior member and a housing, between an inner lens and an outer lens in a dual lens system, or between the housing and the body of the vehicle or a member attached or molded thereto. Further, the resilient deflection member may be the exterior member itself or the housing itself. The resilient deflection member permits the exterior member or other components of the body subassembly to move upon impact without damage to itself or any other surrounding assembly components, and may be used as a styling element to enhance the aesthetic effect of the vehicle.

Abstract: A wheel cover retention system for a wheel having a plurality of lug studs extending through the wheel. The wheel cover includes a base having an outboard surface and an inboard surface opposite the outboard surface, and also having lug towers formed integrally therein and projecting inboard from the inboard surface. The wheel cover includes thermal isolator itegrally fixed coaxially and apically to each of the lug towers, each lug stud extending through each lug tower and each thermal isolator. A lug nut threads to each lug stud to fasten the wheel cover between the wheel and a shoulder on the lug nut. The thermal isolator thermally isolates the base of the wheel cover from heat transfer from a brake component through the lug stud and nut.

Abstract: A composite wheel assembly includes a wheel having a trim ring, a cladding, and a hubcap attached to the wheel. The wheel includes a disc and a rim flange circumscribing the disc with the disc and rim flange defining an outboard surface of the wheel. A trim ring mounts to and radially locates with respect to the rim flange and radially extends inward toward the disc. The cladding mounts to and radially locates with respect to the disc and radially extends outward toward the rim flange. The cladding overlaps the trim ring so that a continuous bright appearance extends across the entire outboard surface of the composite wheel assembly and so that any radial dimensional variation in the trim ring and cladding is taken up by the overlapping relationship therebetween.

Abstract: A composite vehicle wheel having a disk, a rim circumscribing the disk, and an ornamental metal-plated plastic overlay attached to the outboard surface of the disk. The overlay has a pair of oppositely disposed surfaces which form interior and exterior surfaces of the overlay. The interior surface mates with at least a portion of the outboard surface of the wheel while the exterior surface has a metal layer plated thereon. The overlay is formed from a relatively thin plastic panel such that the exterior surface uniformly and closely conforms to the outboard surface of the wheel and the metal layer is substantially flush with the adjacent portions of the outboard surface to provide a pleasing aesthetic effect to the wheel. The integrity of the metal layer is such that the overlay successfully meets corrosion resistance requirements for automobile manufacturers' original equipment.

Abstract: An apparatus and method for constructing a wheel assembly by adhesively bonding a wheel cover to a wheel using a bead of foamed-in-place adhesive. As the wheel and wheel cover are assembled together, the bead of foamed-in-place adhesive is compressed between the wheel cover and the wheel, and thereby spreads out therebetween. The method results in a more complete volumetric fill of adhesive between the wheel cover and wheel, and results in a faster cure time of adhesive when compared to the prior art, thereby enabling a reduction in manufacturing cycle time and work-in-process inventory.

Abstract: An ornamental wheel cover integrally retained on the lug nuts of a vehicle wheel that provides positive positioning of the cover to the lug nuts. The cover is provided with a number of elongated tubular extensions axially projecting therefrom that are each partially slotted to provide a plurality of cantilevered fingers. Each finger has an undercut groove that positively positions the cover to the lug nuts of the wheel. When the cover is attached to the wheel, the elongated tubular extensions are aligned with the lug nuts and the cover is moved axially inwardly of the wheel so that the cantilevered fingers separate slightly as they pass over the flange of the lug nut. The wheel cover further includes a wire band retainer to bias the innermost cantilevered fingers into continual engagement with the lug nuts, even during temperatures that would otherwise cause the plastic to distort due to heat creep.

Abstract: A wheel cover snap fastens to stylized lug nuts of a wheel using resilient retainers that are integrally fastened to the wheel cover. The stylized lug nuts correspond and axially extend through apertures in the wheel cover when the wheel cover is assembled to the wheel. The retainers are secured to an inboard face of the wheel cover and correspondingly engage the stylized lug nuts to retain the wheel trim assembly to the wheel such that retainers are not visible when the wheel trim assembly is viewed from a direction normal to the outboard face of the wheel cover. The apertures are sized in relation to annular flanges on the lug nuts and to the resilient tabs of the retainers such that the wheel cover and/or annular flanges of the lug nuts conceal the retainers from view, and thereby provide an uninterrupted chrome appearance.

Abstract: A wheel cover assembly having an array of pocket inserts correspondingly disposed within an array of turbine pockets of a wheel cover for providing multitudes of different decorative wheel appearances. The pocket inserts are fastened to the wheel cover using an integral snap tab arrangement including integral snap tabs that extend in an inboard direction from the inboard surface of the wheel cover and that are disposed around each turbine pocket. The pocket inserts include integral snap tabs, corresponding to the integral snap tabs of the wheel cover, that extend in an inboard direction from an inboard surface of the pocket insert, and thereby interlock with the integral snap tabs of the wheel cover to retain the pocket inserts within the turbine pockets of the wheel cover. Surface treatments of the wheel cover and pocket inserts can be varied to provide a contrasting decorative appearance across the wheel cover assembly.

Abstract: An improved process for permanently attaching an overlay to a wheel disc, wherein the overlay is aligned and spaced apart from the wheel disc. A mold is created by a combination of the overlay, wheel disc and localized nests that engage at predetermined times during foam filling to close the mold. The mold is adequately sealed so that there is no foam leakage as the foam expands to fill the mold and, therefore, no final trimming of excess foam is required. The improved process is capable of accommodating a wheel having turbine openings therein.

Abstract: A lamp system for a vehicle having an impact-absorbing bumper that is designed to be mounted substantially flush with the surrounding vehicle body panels and bumper, and capable of deflecting with the stroke of the impact-absorbing bumper during impact to obviate the need for the lamp to pivot about an anchor point or to be mechanically displaceable with additional hardware. The lamp system is preferably formed from resilient, impact-resistant material, with a deformable resilient deflection member selectively located between the lens and the housing, between the inner lens and the outer lens in a dual lens system, or between the housing and the body of the vehicle or a member attached thereto. Further, the resilient deflection member may be the lens itself. The material for the resilient deflection member must have a yield strength that is adequate to sustain a predetermined degree of deformation, corresponding to the amount of deflection required to deflect with the bumper stroke.

Abstract: A wheel cover retention system includes a wheel having lug studs extending through the wheel, with lug nuts fastened to the lug studs to retain the wheel to the vehicle. A full-face wheel cover includes a base portion having an inboard surface thereon and lug nut passages extending therethrough, and further includes lug towers circumferentially spaced and integral with the base portion. Each of the lug towers is concentric with each of the lug nut passages and extends axially inwardly from the inboard surface of the base portion thereby terminating in an inboard end. Each lug tower is slotted to define cantilevered fingers thereon. A groove located inside each lug tower positively fixes the axial position of each of the lug towers on each of the lug nuts.