Patent Publication Number: US-2009225561-A1

Title: Illuminated panel portion for vehicles and vehicular accessories

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     The present continuation-in-part application claims priority from and the benefit of U.S. patent application Ser. No. 11/697,758, filed Apr. 9, 2007, and U.S. patent application Ser. No. 10/961,998 (now U.S. Pat. No. 7,232,246), filed Oct. 8, 2004, both entitled Illuminated Panel Portion for Vehicles and Vehicular Accessories, which applications are hereby incorporated herein fully by reference. 
    
    
     BACKGROUND OF THE INVENTION 
     The present invention generally relates to illuminated panel portions for vehicles and vehicular accessories. More specifically, the present invention relates to an illuminated panel portion including a generally translucent panel with an outer surface that is substantially flush with the outer surface of the adjacent panel of vehicles and vehicular accessories for illuminating a selected design defined by the translucent panel. 
     Illuminated devices for vehicles and vehicular accessories have been traditionally used to enhance the visibility of the vehicle or passenger. Also, illuminated devices have served to illuminate selected designs such as indicia, emblems, pictures, outlines, or other such artistic and other designs. 
     A number of illuminated devices have been designed to be mounted on various vehicle or vehicular accessory surfaces. For example, U.S. Pat. No. 6,190,026 describes an illuminated automotive emblem for a motor vehicle having a translucent display template that is illuminated from behind by a light source. U.S. Pat. Nos. 5,615,940 and 5,479,324 describe an illumination device mounted on a gas tank or shell. 
     These and other prior illumination devices are typically mounted onto or protrude from the surfaces of the vehicle or vehicular accessory. Such a mounting arrangement can actually increase the possibility of damage to the underlying machinery or circuitry protected by the support surface. For example, water may seep and pool between the mounting surface of the illumination device and the surface of the vehicle or vehicle accessory. If the illumination device covers an aperture in the vehicle or vehicle accessory surface, water can sometimes seep under the mounting surface of the illumination device and damage underlying machinery or circuitry. 
     Illumination devices are also typically mounted or protrude above the surface of the vehicle or vehicular accessory. This mounting arrangement alters the preexisting contour of the surface. By altering the contour of the vehicle or vehicle accessory surface, the aerodynamics, appearance or aesthetics, and performance of the vehicle and/or accessory may also be compromised. These potential drawbacks may be a disincentive for consumers to mount or install such illumination devices on their vehicles and/or vehicular accessories. 
     In a variation of the above mounting techniques, U.S. Pat. No. 6,439,589 shows a mounting arrangement in which the desired design of the indicia is cut from the surface of the vehicle or vehicular accessory. This arrangement causes the edges of the cut-out portion to be raised above the outer surface of the illumination device. Moreover, because the indicia is cut out, the complexity of the indicia design is necessarily limited in order to maintain the structural integrity of the support surface of the vehicle or the vehicular accessory. 
     Therefore, it is an aspect and object of this invention to provide an illuminated panel portion including a generally translucent panel with an outer surface which avoids one or more of the drawbacks of prior illumination devices. 
     SUMMARY OF THE INVENTION 
     In accordance with one aspect of the present invention, an illuminated panel portion for vehicles or vehicle accessories is provided comprising a generally translucent panel defining a selected design. The translucent panel is disposed in an aperture of an adjacent panel of the vehicle or vehicle accessory such that the outer surfaces of the translucent panel and adjacent panel are substantially flush. A light source is disposed in relation to the translucent panel for illuminating the translucent panel. 
     The relationship between the translucent panel and the adjacent panel may be achieved in various ways. The translucent panel of the illuminated panel portion may include an outer edge and the adjacent panel may further include an edge defining the aperture in the adjacent panel such that the outer edge of the translucent panel is generally adjacent to the edge of the adjacent panel. The outer edge of the translucent panel may also be beveled, and the edge of the adjacent panel may be beveled in complementary fashion. 
     The selected design may also be defined by the translucent panel in various ways. For example, the outer edges of the translucent panel may define the selected design. Alternatively, the translucent panel may include an etched surface defining the selected design. In yet another alternative embodiment, the translucent panel may further comprise a generally opaque layer for defining a generally opaque area and a generally translucent area defining the selected design wherein the generally translucent area is illuminated by the light source. 
     In accordance with yet another aspect of the present invention, a method for making an illuminated panel portion for vehicles or vehicle accessories is further provided wherein an aperture is formed in a panel of the vehicle or vehicle accessory. A translucent panel defining a selected design is disposed in the aperture of the panel such that the outer adjacent surface of the panel and the outer surface of the translucent panel are substantially flush. A light source is further disposed in relation to the translucent panel for illuminating a selected design defined by the translucent panel. 
     The method for making the illuminated panel portion may further include shaping the translucent panel to the contour of the adjacent panel and/or beveling the respective edges of the translucent panel and adjacent panel in a complementary fashion. 
     It should be understood that the present invention includes a number of different aspects or features which may have utility alone and/or in combination with other aspects or features. Accordingly, this summary is not exhaustive identification of each such aspect or feature that is now or may hereafter be claimed, but represents an overview of certain aspects of the present invention to assist in understanding the more detailed description that follows. The scope of the invention is not limited to the specific embodiments described below, but is set forth in the claims now or hereafter filed. 
    
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS 
         FIG. 1  is an exploded perspective view illustrating the molding of a translucent material for defining a selected design to a body panel of a motorcycle in accordance with one embodiment of the present invention. 
         FIG. 2  is an exploded perspective view illustrating the translucent panel formed from the translucent material of  FIG. 1  being positioned in an aperture defined by the body panel of  FIG. 1  in accordance with one embodiment of the present invention. 
         FIG. 3  is a cross sectional view illustrating the engagement of beveled edges of the translucent panel and the adjacent body panel when the translucent panel is disposed in the aperture defined by the body panel as shown in  FIG. 2  in accordance with one embodiment of the present invention. 
         FIG. 4  is a perspective view illustrating the sanding of epoxy on the inner surface of the translucent panel-body panel engagement in accordance with one embodiment of the present invention. 
         FIG. 5  is a perspective view illustrating the selected design on the motorcycle in accordance with one embodiment of the present invention. 
         FIG. 6  is an exploded perspective view illustrating the translucent panel formed from the translucent material of  FIG. 1  being positioned in an aperture defined by the body panel of  FIG. 1 .  FIG. 6  further shows a light source disposed in relation to the translucent panel for illuminating the translucent panel in accordance with an aspect of the present invention. 
         FIGS. 7   a - 7   f  illustrate the cross-section of various aspects of the present invention. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     The illuminated panel portion as described in the present invention may generally be used in illuminating a translucent panel at a number of different locations on vehicles or vehicular accessories. For example, in order to enhance visibility and/or aesthetic quality of the vehicle, illuminated panel portions may be incorporated on the body panel, fender, bumper, hood, faring, or other such areas of the vehicle. Examples of vehicles which may accommodate illuminated panel portions include trucks, cars, motorcycles, boats, airplanes, snowmobiles, off-road vehicles, or any other vehicle. Illuminated panel portions may further be implemented in vehicular accessories such as helmets, trailers, luggage carriers, or any other such vehicle accessory. 
     For purposes of illustration and not limitation, the present invention is described below in the context of an illuminated panel portion including a generally translucent panel having an outer surface which is substantially flush to the outer surface of the adjacent motorcycle body panel for illuminating a selected design. As described above, however, it is important to note that the illuminated panel portion and method of installing such may be implemented on other areas and in other types of vehicles or vehicular accessories. 
     The term “panel” as used herein is intended to have a broad meaning. Panel may represent a separate or distinct part of a surface area of some extent. This surface area may be larger or smaller as desired without departing from the present invention. For example, as discussed in detail below, the translucent panel may be larger than the selected design. Alternatively, the translucent panel may also be sized and shaped such that the translucent panel itself constitutes the selected design. Regarding the adjacent panel, the adjacent panel may be a portion the body panel, fender, bumper, hood, or other such areas of a vehicle. Alternatively the adjacent panel may be a portion of a helmet, trailer, luggage carrier, or any other such vehicle accessory. 
       FIG. 1  illustrates a body panel  10  of a motorcycle  12  wherein a selected design  14  is to be incorporated and illuminated. In forming the illuminated panel portion, a generally translucent material  16  is provided preferably in the form of cast acrylic, although other materials may alternatively be used which are generally transparent or translucent to allow light to pass therethrough. 
     To form the desired shape, the translucent material  16  is also preferably moldable, such as being thermoplastic. In this embodiment, the translucent material  16  is heated to a temperature of preferably 240° F. such that it becomes malleable. The thickness of the translucent material  16  may be about the same thickness of the body panel  10 , although it may also be thinner or thicker as desired, without departing from the present invention. In the illustrated installation, the thicknesses of the translucent material  16  and the body panel  10  are each about 0.25 inches (6.3 mm) thick. 
     The heated translucent material  16  is placed onto the outer surface of the body panel  10  on the area where the translucent material  16  will be installed, and pressed against the outer surface such that it molds or conforms to the contour of the body panel  10 . It is important to note that other molding or forming methods may also be used, such as cast molding using resin or other generally liquid molding material, plug molding, machining, and other such molding or forming methods. 
     Now referring to  FIGS. 2 and 3 , an area larger than the outline of the selected design  14  is cut from the translucent material  16 , thereby forming a translucent panel  18 . A beveled edge  20  may be formed on the outer edge of the translucent panel  18  by beveling this outer edge from the inner surface of the translucent panel. 
     An aperture  22  in the body panel  10  is cut or otherwise formed such that the translucent panel  18  is slightly smaller the aperture  22 . A beveled edge  24  is formed on the edge defining the aperture  22  in the body panel  10  by beveling this edge from the outer surface of the body panel  10 . 
     Referring to  FIG. 3 , the translucent panel  18  is disposed in the aperture  22  of the body panel  10  such that the edge of the translucent panel  18  is generally adjacent to and flush with the body panel  10 . Although the flush relationship may be achieved in various ways, in the illustrated embodiment, the edge  20  of the translucent panel  18  is beveled from the inner surface of the translucent panel  18 , whereas the edge  24  defining the aperture  22  in the body panel  10  is beveled from the outer surface of the body panel  10 . Therefore, these beveled edges  22 ,  24  are beveled in complementary fashion that allows the edge of the panels to support one another and the outer surface to be generally flush. 
     Specifically, the beveled edge  24  defining the aperture  22  in the body panel  10  supports the beveled edge  20  of the translucent panel  18  when the translucent panel  18  is disposed in the aperture  22  of the body panel  10 . Accordingly, in this embodiment, the body panel serves as a support surface for the translucent panel  18 . The beveled edges  22 ,  24  further provide for a substantial engagement area between the translucent panel  18  and the body panel  10 , allowing for a better bond between the edge  22  of the translucent panel  18  and the edge  24  defining the aperture  22  in the body panel  10 . 
     It is important to note that the edges of the translucent panel  18  and that defining the aperture  22  in the body panel  10  do not necessarily need to be beveled. It is further not required that the body panel  10  serve as a support surface for the translucent panel  18 . Instead, the translucent panel  18  merely needs to be disposed in the aperture  22  of the body panel  10  such that the outer surface of translucent panel  18  and the outer surface of the adjacent body panel  10  are substantially flush. 
     The translucent panel  18  may further be affixed to the body panel  10  in various ways. For example, the inner surface of the translucent panel may be taped or mechanically fastened (e.g., using brackets) to the inner surface of the body panel. 
     In yet another example, referring to  FIG. 4 , the translucent panel  18  is secured to the body panel  10  with a suitable bonding material  26 , preferably a non-shrinking epoxy. This bonding material  26  is applied to the junctures between the translucent panel  18  and the body panel  18  at both the inner and outer surfaces. When the bonding material  26  cures, the outer surface is sanded smooth with a sanding device  28  such that all the sharp edges are feathered smooth. Plastic body fillers are further applied to correct any imperfections therein. Suitable fillers include fiberglass mixture fillers, polyester fillers, hardest resin fillers and/or any other such fillers (e.g., BONDO® fiberglass resin manufactured by the BONDO® Corporation). 
     The translucent panel  18  may define the selected design  14  in various ways. In one embodiment, paint which dries generally transparent or translucent (e.g., shown by  20  or  30  in  FIGS. 7   b  and  7   c , respectively) may be painted on the translucent panel  18  such that when the translucent panel  18  is illuminated a colored light effect is achieved. These paints are generally known in the art as candy colored paints. 
     In another embodiment, the outer edges of the translucent panel may in itself define the selected design. In this case, the translucent panel may have generally the same size and shape of the selected design. 
     In yet another embodiment, which is shown in  FIG. 15  and more particularly  FIGS. 7   a - 7   f  herein, opaque layers  32   a ,  32   b  may also be added to either the inner or outer surface of the translucent panel  18  to define generally translucent and generally opaque areas  32   a ,  32   b  in the translucent panel  18 . For aesthetics, these opaque areas  32   a ,  32   b  may be of the same color as the body panel  10  in order to match the body panel color and the areas not covered by the opaque layer  32   a ,  32   b  remain translucent for back-illumination. 
     In an illustrative example of applying an opaque layer  32   a ,  32   b , a sticker mask for the selected design  14  may be affixed to the outer surface of the translucent panel  18 . This sticker mask may serve as a stencil for the selected design. Alternatively, the selected design  14  may be etched onto either the outer or inner surface of the translucent panel  18  (e.g., as shown et  34   a  and  34   b  in  FIGS. 7   e  and  7   f ). If the selected design  14  is etched, a sticker mask may cover the etched design. 
     After the sticker mask is applied, the entire outer surface is sealed with an epoxy sealer and a coat of paint is applied. Paint matching the color of the body panel  10  may be used in conjunction with the stencil. In this manner, the areas covered by the sticker mask define translucent areas, whereas the areas left uncovered define opaque areas  32   a ,  32   b  after removal of the mask. Accordingly, if the sticker mask serves as a stencil for the selected design  14 , the areas covered by the sticker mask in the form of the selected design  14  is left translucent, whereas the area left uncovered is painted to define an opaque area matching the color of the body panel  10 . Alternatively, if the selected design  14  is etched onto the translucent panel  18  (e.g., as shown at  34   a  and  34   b  in  FIGS. 7   e  and  7   f , the sticker mask may be used to cover the selected design  14  such that the area covered is left translucent. 
     In yet another embodiment, a permanent sticker mask is applied to portions of the body panel  10  to define opaque and nonopaque areas. Where the permanent sticker mask is applied, the translucent areas to be illuminated are not covered by the sticker mask. In yet another embodiment, a sticker mask with transparent portions and nontransparent portions, colored or uncolored, is applied to the entire surface of the body panel  10 . This full-panel mask is left in place and then may be covered by a clear coating  36  as described above or may also be left without a clear coating as desired. One example of a contemplated sticker mask is a polymer based sheet such as vinyl wrap or covering with an adhesive backside or using a prayed on adhesive for placement upon a body panel  10  or as different masks in adjacent segments to cover a larger area of a vehicle. 
     After the sticker mask is removed, a clear urethane coating  36  may be applied to the entire outer surface. The removal of the sticker mask may cause an uneven surface with raised edges. In that event, the outer surface may be wetsanded and additional clear urethane coatings  36  are applied to achieve a smooth, lustrous finish. This process of wetsanding and applying additional clear urethane is repeated until a smooth, even surface is achieved. 
     A light source  38  as shown in  FIG. 6  is disposed in relation to the translucent panel  18  (typically behind the panel) for illuminating the translucent panel  18 . As illustrated in  FIG. 5 , the resulting effect is a translucent area being in the form of the selected design  14  being illuminated, whereas the opaque areas are painted to match the body panel  10 . The light source may be an LED, incandescent, neon, or any other chosen light source. The light source may further be connected to various functional components of the vehicle. For example, the light source may be connected to the turn signal mechanism or brakes, thereby providing enhanced visibility of the turn signal or brake. Alternatively, if the illuminated panel portion were installed in a helmet or on the back of a vehicle, the light source may be connected to signal when vehicle&#39;s brakes are engaged (e.g., through hard wiring or wireless transmission means). 
     It will also be understood that this description shall not be construed in a limiting sense. Rather, various changes and modifications can be made to the illustrative embodiments without departing from the true spirit and scope of the invention, as defined by the following claims. Furthermore, it will be appreciated that any such changes and modifications will be recognized by those skilled in the art as an equivalent to one or more elements of the following claims, and shall be covered by such claims to the fullest extent permitted by law.