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 process for preparing a chrome substrate for application of a polymer coating, wherein the substrate preparation enhances adhesion and durability of the adhesion between the chrome substrate and the polymer coating, involves contacting the chrome substrate with an acid solution for a period of time sufficient to modify the surface of the chrome substrate. In certain embodiments, the acid treatment is an anodic treatment. In accordance with certain aspects of this invention, the acid treated chrome surface is further treated with a silane compound to enhance adhesion with a subsequently applied polymer coating composition.

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: A lamp assembly provides an integrated flexure member/bezel extending between a lamp lens and a housing for the lamp reflector. The flexure member has forward and rearward peripheral edges shaped to conform to the mating shapes of the lens and housing, respectively, for holding the elements together. The flexural member has internal surfaces which extend rearwardly toward the reflector surrounding the edges of the reflector such that no gaps are visually present and which can be metalized such that the overall lamp assembly has a shiny appearance.

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 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: 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 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 lamp assembly provides an integrated flexure member/bezel extending between a lamp lens and a housing for the lamp reflector. The flexure member has forward and rearward peripheral edges shaped to conform to the mating shapes of the lens and housing, respectively, for holding the elements together. The flexural member has internal surfaces which extend rearwardly toward the reflector surrounding the edges of the reflector such that no gaps are visually present and which can be metalized such that the overall lamp assembly has a shiny appearance.

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 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 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 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 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.