Abstract: A headlamp and/or taillamp system having an impact-absorbing bumper that is designed to be mounted substantially flush with the surrounding vehicle body panels and bumper, while also being capable of deflecting with the stroke of the impact-absorbing bumper during impact to obviate the need for the headlamp and/or taillamp to pivot about an anchor point or to be mechanically displaceable with additional hardware. The headlamp and/or taillamp is preferably formed from resilient, impact resistant material, such as a high impact plastic, in combination with a deformable flexure member that is located selectively between the lens and the vehicle to resiliently respond to impact. The material for the flexure member must be selected to 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 method for plating a high impact resistant plastic, particularly a polycarbonate substrate which has been modified with up to about 50 percent by weight of acrylonitrile-butadiene-styrene. The surface of the plastic is first conditioned with a halogenated organic solvent conditioner, preferably 1-3-dichloro-2-propanol, prior to the electrochemical deposition of the desired metal layer.

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 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 lug nuts preferably have a flange that defines an upper shoulder. The cover is provided with a number of elongated tubular extensions axially projecting from the cover that are each partially slotted to provide a plurality of cantilevered fingers. Each finger has an undercut groove that has a shoulder which positively positions the cover to the upper shoulder of the lug nuts of the wheel. Below the undercut groove is a bulbous portion that contacts the lug nut below the flange. 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 the bulbous portions pass over the flange of the lug nut.

Abstract: A process for metal plating a high impact, high temperature plastic suitable for forming trim elements of an automobile. The process is particularly directed to plating an elastomer-modified PPA resin, and entails closely controlled process steps that include selectively etching the elastomer and the PPA matrix with a solution containing chromic acid, then effectively removing from the substrate any retained chromium which would adversely affect the ability of metal plating to adhere to the substrate, and thereafter protecting the substrate from attack by sulfuric acid. The process is particularly effective for electroplating a PPA resin modified with about five to about 30 weight percent EPDM.

Abstract: A process for metal plating a high impact, high temperature plastic suitable for forming trim elements of an automobile. The process is particularly directed to plating an elastomer-modified PPA resin, and entails closely controlled process steps that include selectively etching the elastomer and the PPA matrix with a solution containing chromic acid, then effectively removing from the substrate any retained chromium which would adversely affect the ability of metal plating to adhere to the substrate, and thereafter protecting the substrate from attack by sulfuric acid. The process is particularly effective for electroplating a PPA resin modified with about five to about 30 weight percent elastomeric materials.

Abstract: An apparatus and method for assembling to an automotive wheel an overlay composed of a solid plastic panel member that is directly attached to the surface of the wheel. In one aspect, an intermediate positive fixing element is provided for temporarily positioning and securing the overlay to the wheel during an interval in which a slow-curing, high strength adhesive that permanently adheres the overlay to the wheel is allowed to cure. An interrelated aspect involves the selective placement of adhesive between the overlay and the wheel so as to improve the overall manufacturability, performance, and consumer-perceived quality of the resulting wheel assembly.

Abstract: A method for plating a high impact resistant plastic, particularly a polycarbonate substrate which has been modified with up to about 50 percent by weight of acrylonitrile-butadiene-styrene. The surface of the plastic is first conditioned with a halogenated organic solvent conditioner, preferably 1-3-dichloro-2-propanol, prior to electroless plating and the electrochemical deposition of the desired metal layer.

Abstract: A deployment door (24) for an inflatable air bag (18) has a door panel (80), a hinge (84), and first and second stress risers (128,192). The first stress riser (128) ruptures under stress induced in the door panel (80) upon movement of the air bag (18) forcefully against the door panel (80). The hinge (84) supports the door panel (80) for pivotal movement about an axis (190) when the first stress riser (128) has been ruptured. The hinge (84) includes a pivotal hinge leaf (150) having opposite side edges (180,182). One of the side edges (180) extends alongside the axis (190). The other side edge (182) is skewed relative to the axis (190). The second stress riser (192) ruptures under stress induced in the pivotal hinge leaf (150) when the door panel (80) pivots about the axis (190).

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: A method for providing a decorative surface on a standard steel wheel, without requiring the use of the wheel in the production of the decorative surface. The decorative surface of this invention is provided by an overlay composed of a panel which is assembled to the surface of the wheel and which closely conforms to certain portions of the wheel, while being spaced apart from other portions of the wheel in order to form exterior surface contours which contribute an aesthetically pleasing appearance to the wheel. The overlay further includes a spacing feature disposed on the inboard surface of the overlay. The spacing feature is configured to mate with portions of the axial surface of the wheel so as to fill voids between the inboard surface of the panel and the axial surface of the wheel. In doing so, the spacing feature prevents moisture and dirt from becoming trapped within the void between the overlay and the wheel.

Abstract: An apparatus and method for assembling to an automotive wheel an overlay composed of a solid plastic panel member that is directly attached to the surface of the wheel. In one aspect, an intermediate positive fixing element is provided for temporarily positioning and securing the overlay to the wheel during an interval in which a slow-curing, high strength adhesive that permanently adheres the overlay to the wheel is allowed to cure. An interrelated aspect involves the selective placement of adhesive between the overlay and the wheel so as to improve the overall manufacturability, performance, and consumer-perceived quality of the resulting wheel assembly.

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: A wheel and overlay assembly having an overlay that extends to the perimeter of the wheel in order to maximize the aesthetic effect of the overlay, while also accommodating balance weights at the perimeter in order to permit proper balancing of the assembly. The result is a wheel and overlay assembly having a fully integrated appearance in which the two-piece construction of the assembly is more fully concealed. The wheel and overlay assembly is an improvement over prior art assemblies which use an overlay of the type formed separately from the wheel, and particularly overlays formed as a solid plastic panel member that is directly attached to the outboard surface of a wheel. Furthermore, the invention is applicable to both aluminum and steel wheels of the type currently existing in the industry, as well as standardized balance weights utilized in the industry.

Abstract: An automobile grille which is selectively chromium plated so as to promote the flexural properties of the grille. By optimizing the flexural properties of the grille, the grille is more readily capable of withstanding a frontal impact without sustaining permanent damage. Preferably, the chromium plating is selectively deposited on exposed surfaces of the grille so as to minimize the detrimental effect which a hard and brittle chromium plating has on the flexural modulus of the grille. As a result, the grille is more readily able to flex under the load of an impact directed into the grille from the front of the automobile. In addition, chromium plating is deposited on surfaces of the grille which predominantly see compressive loading, so as to reduce the likelihood that the chromium plating will crack in tension. The grille is particularly suitable for mounting flush with an impact-absorbing bumper, such that the grille is capable of resiliently deflecting with the stroke of the bumper.

Abstract: A flexible automobile grille, particularly suited for mounting flush with an impact-absorbing bumper, is capable of resiliently deflecting with the stroke of the bumper. The grille is provided with a dual support arrangement by which an upper edge of the grille is resiliently attached directly to the automobile engine hood, while the lower edge is resiliently supported by support members which interconnect the grille's lower edge to the engine hood. The dual support approach of this invention serves to enable greater stroking of the grille during impact, yet contributes additional rigidity to make the grille relatively unsusceptible to road and aerodynamically induced vibrations, and amenable to physical handling during opening and closing of the engine hood.

Abstract: An automobile grille which is selectively chromium plated so as to promote the flexural properties of the grille. By optimizing the flexural properties of the grille, the grille is more readily capable of withstanding a frontal impact without sustaining permanent damage. Preferably, the chromium plating is selectively deposited on exposed surfaces of the grille so as to minimize the detrimental effect which a hard and brittle chromium plating has on the flexural modulus of the grille. As a result, the grille is more readily able to flex under the load of an impact directed into the grille from the front of the automobile. In addition, chromium plating is deposited on surfaces of the grille which predominantly see compressive loading, so as to reduce the likelihood that the chromium plating will crack in tension. The grille is particularly suitable for mounting flush with an impact-absorbing bumper, such that the grille is capable of resiliently deflecting with the stroke of the bumper.

Abstract: A flexible automobile grille which accommodates the movement of an impact-absorbing bumper. The grille is capable of deflecting with the stroke of the impact-absorbing bumper during impact without the need for the grille to be either pivotable about an anchor point or to be mechanically displaceable with special hardware. The material of the grille is selected to have a yield strength which is adequate to sustain a predetermined degree of yielding corresponding to the amount of deflection required with the bumper's stroke. The grille includes a generally elongated body portion having an upper edge and a lower edge which extend horizontally adjacent the engine hood and the bumper, respectively. Both the upper and lower edges may be configured to attach to the automobile.

Abstract: A remote control rear view mirror which includes a housing having a mirror receptive opening provided therein and a mounting plate that is received in the opening and is fastened to the back wall of the housing, a drive motor unit that includes two separate electric motors in a common housing that is fastened to the mounting plate and are connected to an electrical power source, a mirror glass supporting frame member that has a ball-and-socket connection with the drive motor unit housing and includes a drive connection with each of the electric motors, and a retainer ring that is adapted to be mounted and supported on the mounting plate and to have a pivotal support and be restrictively engaged with the mirror glass supporting frame member.

Abstract: A rear view mirror assembly comprising a housing shell with a mirror glass receptive member that has a spherical surfaced projection on the back side thereof that is received in snap-lock engagement with a gimbal mounted ring in the housing shell so that the two are afforded relative movement therebetween. A gear toothed segment on an extended arm is provided on the mirror glass receptive member which is engaged by a pinion gear mounted on the gimbal ring so that when the pinion gear is turned, via a single strand bowden wire remote control operating structure, the mirror glass receptive member is actuated relative to the gimbal ring to effect a mirror adjustment, and when the pinion gear is moved axially the gimbal ring and the mirror glass receptive member are actuated together to effect a relatively different mirror adjustment movement.