Patent Publication Number: US-2020282925-A1

Title: Light veil

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application claims the benefit of U.S. Provisional Patent Application No. 62/813,245 filed on Mar. 4, 2019, the entire contents of which are herein incorporated by reference. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Field 
     The disclosed embodiments relate generally to the field of automotive exteriors. More specifically, the disclosed embodiments relate to automobile fascia systems and arrangements. 
     2. Description of the Related Art 
     The term fascia is used in the automotive industry in reference to plastic materials used at various locations on a vehicle. Most commonly, fascia panels are implemented into the front and rear of a vehicle. The facias can be incorporated at, e.g., the vehicle&#39;s headlamp area, grill, bumper, side paneling, into or near a taillight arrangement, as well as other locations. 
     In many instances, facias exist as a relatively soft solid plastic pieces that are mounted on top of the bumper underneath the headlights. Normally the facias are incorporated such that they are conformed into an overall front end “look” of the vehicle. This requires that the facias be mounted such that some level of uniformity is created across the front of the vehicle. Additionally, the shape of the devices are normally also incorporated into the aerodynamic design for the vehicle. 
     SUMMARY 
     In an embodiment, a method of making a fascia for an automobile is provided. The method includes providing an article, the article being one of translucent or transparent; applying a deposited pattern onto at least a first portion of a first side of the article; and, forming the article into a shape, the shape being configured to be consonant with a vehicle exterior configuration. 
     In another embodiment, a fascia system is provided. The fascia system includes a transparent member mounted on a vehicle, the member having printed matter on one side of the member; and, the member being included into a vehicle exterior design, the member being oriented in front of an illumination device, the printed matter being illuminated by the device. 
    
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS 
       Illustrative embodiments are described in detail below with reference to the attached drawing figures, which are incorporated by reference herein and wherein: 
         FIG. 1A  shows a top view of a pre-processed clear plastic device and  FIG. 1B  shows the same article from a side view; 
         FIG. 2A  shows a clear plastic device on which printing has occurred on one side, and  FIG. 2B  shows the same device from a side view; 
         FIG. 3A  shows the device shown in  FIGS. 2A and 2B  after it has been formed prior to installation, and  FIG. 3B  shows the same device from the side; 
         FIG. 4  shows the completed device as it might be installed on a vehicle; and 
         FIG. 5  shows a lighting arrangement concealed behind the device. 
     
    
    
     DETAILED DESCRIPTION 
     Embodiments provide systems including a decorative fascia and a related method for making the device. More specifically, a light veil is created by printing matter on one side of a clear or translucent article, then optionally bending, molding, or otherwise conforming the article into a particular shape for the purpose of being installed into a desired vehicle exterior configuration. In some embodiments, the processed article is shaped to be consonant with an overall vehicle exterior design in terms of not only shape, but color. In other embodiments, the article is additionally designed to include additional designs intended to be animated by illumination created behind the article once processed and installed. In still other embodiments, the matter is printed on the interior side of the article where it is protected from the elements. 
     An embodiment is disclosed in  FIGS. 1-5 . Referring first to  FIGS. 1A-B , a flat clear (or alternatively translucent) plastic member  100  is shown from a top view ( FIG. 1A ) and a side view ( FIG. 1B ). As is shown in  FIG. 1B , plastic member  100  has a first “A” side  102 , a second “B” side  104 , and a first end  112  and a second end  114 . One of the two sides (A or B) will be, when the article is installed onto a vehicle, on the exterior, and the other will be in the interior. The panel, in embodiments is formed as an obtuse triangle defined by a first, a second, and a third side,  106 ,  108 , and  110  respectively. Sides  106  and  108  form an acutely angled corner at a sharp point  112 . Sides  106  and  110  form a second acutely angled corner at a point  114 . Sides  108  and  110  form an obtusely angled corner  116 , but corner  116  has been rounded. 
       FIG. 1B  shows the same article from a side view, and in this view it can be seen that the member  100  is flat (which makes it better for receiving print), and has a consistent thickness. In selecting a material, it is possible that a clear thermoplastic, e.g., Polycarbonate, Poly(methyl methacrylate) (PMMA), Polypropylenes (PPs), Natural PP, Polycarbonate (PC) blended with Acrylonitrile Butadiene Styrene polymer (ABS), Natural PC/ABS, or numerous other substances could be used. Preferably ones which are transparent, or at least translucent, are moldable, and in embodiments, are capable of receiving ink-jet printing. 
     To meet the design demands for a vehicle on which the panel will later be installed, the panel  100  may have to be cut from a sheet or other configuration. The sheet thickness selected could be thicker or even thinner than what is shown in the figures, which are intended to be exemplary only. Alternatively, the panel  100  can be formed into the shape desired according to some process, rather than cut. 
     Once the flat panel  100  has been cut or otherwise formed into the desired shape, it is printed with an ink or other coating on one of the two sides (A or B). In some embodiments, the inside surface  104  can be selected in order to avoid exposure to the elements (wind and weather). In other embodiments, the ink could be applied to the outside  102 , e.g., if necessary, to create a desired look, or create consonance with a surrounding design scheme. 
     The printing processed used could be an inkjet printing process. More specifically, a flatbed or other type of printer could be used. Alternatively, the printing could be done using a multi-axis robotic system (e.g., the inkjet head could be mounted on a robotic arm). This robotic system could be used to print onto non-flat, e.g., three-dimensional surfaces if desired. The flatbed sorts of printers involve the placement of the article on a supporting surface, and one or more print heads deposit ink onto the plastic from above. The printed matter, ordinarily, will be instantaneously dried using ultraviolet light (UV) during the printing process. Further, some printing units also enable the deposition of protective coatings atop the ink once deposited. For example, for polycarbonate panels, hard coat can be applied prior to any forming for the purpose of providing UV protection. 
     In embodiments, an ink can be deposited onto one of sides  102  or  104 , and then optionally, a coating deposited on top of the printed matter using the same, or some additional processing device. Alternatively, a lithographic (litho) press, digital press, or other system enabling printing onto plastic could be used. Additionally, the ink selected for use can be fade resistant if the intended installation on the vehicle involves exposure to direct or indirect sunlight regardless of the side ink is printed onto. 
       FIG. 2A  shows the backside  104  of the panel  100  once it has been printed. Two distinct portions,  118  and  120  are created in the panel (can be seen through the panel, and the print is on the back side). As can be seen, in this embodiment, a decorative configuration has been printed in a portion  118  of the panel  100 . More specifically, a honeycomb pattern has been created in which transparent wall cross sections  122  divide more occlusive cells  124 . On another portion  120  of the panel  100 , a solid color has been painted, and there is no pattern. This panel might be translucent, or in some embodiments could be printed to totally occlude light. Alternatively, distinct or common decorative patterns could be printed on either or both/all portions. It should be considered that numerous portions of any panel could be painted in any variety of manners in order to accomplish vehicle exterior design objectives. Here, as an example, the two distinct portions  118  and  120  of the panel  100  exist on the other side of what will be a fold formed about an axis A (see  FIG. 3A ) once the panel is subjected to a forming process. 
     After the ink and any coatings have been deposited and dried, the article can be subjected to a forming process. In this forming process, the article is typically subjected to elevated temperatures, and then pressed onto a mold. In the  FIGS. 2-3  embodiment, the mold is used to create a fold about an axis A, as shown in  FIG. 3A . This creates a first planar part  130  which is angled relative to a second planar part  132 . In the disclosed embodiment, the first planar part  130  displays the decorative arrangement where light passes through some of the design unmodified (the clear honeycomb walls  122 ) and includes other portions that modify the light (the cells  124 ). The second planar part  132 , in the disclosed embodiment, is solid and occludes or otherwise modifies the light. Those skilled in the art will recognize that numerous other processes could be used in the alternative. Regardless, once the process is complete, the panel, in the disclosed embodiment, looks like what is disclosed in  FIGS. 3A  and B. The processed form shown in  FIGS. 3A-B  is only exemplary, and those skilled in the art should recognize that printed members, other than being folded, could be formed into any number of simple or complex shapes for the purpose of being conformed into some particular vehicle design. 
     It should be noted that, although in the disclosed embodiments the starting preprocessed member is flat, printed, and then formed, it is also possible that the article could be initially of some more complex shape, and that some sort of three-dimensional printing be performed to decorate simple, or even complex surfaces on the thing. 
       FIG. 4  shows how a fully-processed article can be incorporated into a portion of an ultimate vehicle exterior design. As can be seen, fully formed panel  100  is incorporated with surrounding structures (e.g., surrounding fascias  136  and  138 ) such that the edges match up, and such that it is fluid with the surrounding surface configurations as a part of an overall design. The incorporation here is made into the area beneath the vehicle headlight  134 . 
       FIG. 5  discloses how a lighting arrangement can be used to illuminate the fully formed panel from behind. For example, upper panel  132  can be selectively illuminated using an upper LED PCB arrangement  140  (e.g., for embodiments where the upper panel  132  is not completely occlusive). Dual lower LED PCB arrangements  142  and  144  are provided to illuminate the lower panel. In embodiments, the LED arrangements  140 ,  142 , and  144  can be separately controlled, and in embodiments can be used to create animations of various designs printed onto the inside surface  104 . Again, in the disclosed embodiments, the top portion  132  of panel  100  above the bend is printed with a solid color, and is made to be occlusive or translucent. Where portion  132  is totally occluded, there would be no need for the LEDs  140 . In the disclosed embodiment where lower portion  130  is made to have the honeycomb configuration shown in the earlier  FIGS. 2-4 , the lights  142  and  144  could be used to simply illuminate the pattern at night, or to blink, or to create some other sort of animation. The lighting could be automatic, or manually controlled. Any of the LEDs can be used to selectively or dynamically illuminate the printed graphic created. Regardless, an ornamentally pleasing illuminated effect can be created, and even include animation where automated. Further, the lower and upper LEDs could all be configured to illuminate together in a coordinated manner under control of a controller. 
     Also shown in  FIG. 5  is an optional incorporation of a light-homogenizing optical sheet  146 . Optical sheet  146  is mounted, in the disclosed embodiment, on a peripheral rib  150 . Rib  150  travels all about the periphery of the inside surface  104  of the lens  132 . The ribs create a gap  148  between the inside surface  104  and the optical sheet  146 . The optical sheet, in embodiments, is intended to homogenize the light received from the light sources  140 ,  142 , and  144  before it is introduced through the portions  130  and  132  of the lens. 
     Many different arrangements of the various components depicted, as well as components not shown, are possible without departing from the spirit and scope of what is claimed herein. Embodiments have been described with the intent to be illustrative rather than restrictive. Alternative embodiments will become apparent to those skilled in the art that do not depart from what is disclosed. A skilled artisan may develop alternative means of implementing the aforementioned improvements without departing from what is claimed. 
     It will be understood that certain features and sub-combinations are of utility and may be employed without reference to other features and subcombinations and are contemplated within the scope of the claims. Not all steps listed in the various figures need be carried out in the specific order described. 
     Features described above as well as those claimed below may be combined in various ways without departing from the scope hereof. The following examples illustrate some possible, non-limiting combinations: 
     (A1) A method of making a fascia for an automobile may include the steps of: (i) providing an article, the article being one of translucent or transparent; (ii) applying a deposited pattern onto at least a first portion of a first side of the article; and (iii) forming the article into a shape, the shape being configured to be consonant with a vehicle exterior configuration. 
     (A2) For the method denoted as (A1), using a printing process to accomplish the applying step. 
     (A3) For the methods denoted as either or both of (A1) or (A2), executing the printing process using an inkjet printing process. 
     (A4) For the methods denoted as one or more of (A1) through (A3), executing the printing process using a flatbed printer. 
     (A5) For the methods denoted as either or both of (A1) or (A2), executing the printing process using a multi-axis robotic system. 
     (A6) For the methods denoted as one or more of (A1), (A2), or (A5), using an inkjet head mounted to the multi-axis robotic system to print the deposited pattern onto a non-flat three-dimensional surface of the article. 
     (A7). For the methods denoted as one or more of (A1), (A2), (A5), or (A6), drying the deposited pattern on the article using ultraviolet (UV) light. 
     (A8) For the method denoted as (A1), depositing a protective coating atop the ink once deposited. 
     (A9) For the method denoted as (A1), selecting a flat member to serve as the article in the providing step; and configuring the article into a non-flat shape during the forming step. 
     (A10) For the method denoted as (A1), selecting a substantially transparent material to comprise the article in the providing step; allowing the first portion, once subjected to the deposited pattern, to retain at least portions of transparency or translucence; and depositing a substantially occlusive ink or paint onto a second portion of the first side of the article. 
     (A11) For the method denoted as (A1), configuring the shape of the article during the forming step such that the first side of the article is internal, thus protecting the deposited pattern against the elements. 
     (A12) For the method denoted as (A1), selecting, in the providing step, a clear thermoplastic as a material for which the article is constructed. 
     (A13) For the methods denoted as either or both of (A1) and (A12), selecting one of Polycarbonate, Poly(methyl methacrylate) (PMMA), Polypropylenes (PPs), Natural PP, Polycarbonate (PC) blended with Acrylonitrile Butadiene Styrene polymer (ABS), or Natural PC/ABS as the thermoplastic. 
     (A14) For the method denoted as (A1), installing the article onto a vehicle after the forming step and causing the deposited pattern to be animated by illumination created behind the article. 
     (A15) For the methods denoted as either or both of (A1) and (A14), creating the animation by selectively turning on and off different LEDs in a plurality of LEDs. 
     (A16) For the method denoted as (A1), the providing step including cutting the article from a sheet to create an initial flat shape. 
     (A17) For the method denoted as either or both of (A1) and (A16), cutting the article such that the flat shape is generally triangular, and has sharp and rounded corners. 
     (A18) For the method denoted as (A1), using one of a lithographic press or digital press to accomplish the applying step. 
     (A19) For the method denoted as (A1), the forming step further comprising: heating, molding, and then cooling the article to create a permanent fold in the article, the fold contributing to an ultimate configuration of the article, the ultimate configuration being consonant with surrounding fascia configurations in an automotive design. 
     (A20) For the method denoted as either or both of (A1) or (A19), the heating, molding, and then cooling steps further comprising: leaving first and second planar portions on either side of the permanent fold, the permanent fold serving as a transition between the deposited pattern and a remaining portion of the article. 
     (A21) For the method denoted as one or more of (A1), (A19) or (A20), depositing a different pattern onto the remaining portion of the article. 
     (A22) A fascia system including: a transparent member mounted on a vehicle, the member having printed matter on one side of the member; and the member being included into a vehicle exterior design, the member being oriented in front of an illumination device, the printed matter being illuminated by the device. 
     (A23) The fascia system denoted as (A22) where different portions of the member being configured to be all of: (i) substantially occlusive, (ii) patterned, and (iii) either transparent or translucent. 
     (A24) The fascia system denoted as (A22) having a homogenizing optical sheet between the illumination device and the transparent member.