Abstract:
An automotive display panel having a plurality of clear plastic substrates, wherein color-printed inks or foils are imprinted on the substrates. Each plastic substrate includes digits and identifying marks in selected areas. After creating a metallic-looking finish on the substrates, finely configured lines, such as concentric circles or radial lines, are printed on the color-tinted layer to create a desired appearance. Thereafter,,when the printing is completed, the substrates may be formed in multi-level configurations for providing a three-dimensional appearance. Backlighting is also provided to illuminate the selected areas of the substrates.

Description:
BACKGROUND OF THE INVENTION 
     This invention relates to automotive display panels, and, more particularly, to an improved vehicle information panel for use in automotive dashboards. 
     Various types of vehicle information panels have been developed for the purpose of meeting customer demands with respect to styling and visibility. Automotive display panels in dashboards also need to be made from a combination of materials that are able to survive automotive quality control requirements at affordable pricing. 
     In connection with styling, known automotive display panels do not provide an aesthetically striking appearance. Instead, the appearances for many of the existing automotive display panels are lacking in aesthetic appeal. It is, therefore, an object of the invention to provide a more aesthetically attractive panel while improving the visibility of the information displayed. 
     Automotive display panels are currently decorated for day and night displays. The decoration typically includes a black background with information printed on the black background in a desired color, typically white. The decoration on the panel may include other colors that are different from the daytime white such that the panel information is visible at night as a result of lighting. 
     Other known automotive display panels have deficiencies, such as cost. There has been a need for alternative automotive display panels to satisfy styling and quality control requirements at competitive pricing. 
     While various types of automotive display panels have been developed with a view to meet demands of vehicle users, these attempts have not produced satisfactory results. For example, one approach involves fluorescent or pigmented inks that are applied to the indicating portions of the display, such as patterns and characters. The fluorescent material then radiates light with a specific color in response to illumination of light on the display. Nevertheless, these prior techniques do not produce satisfactory results because the indicating portions lose sharpness under certain conditions. Further, these known automotive displays fail to meet the vehicle users&#39; demands for styling, especially in high-end vehicles. 
     In other areas, such as marketing, displays have been designed to increase the appeal of the products and to make the products more attractive to potential purchasers. For example, fanciful displays and designs have been used on cards, packaging materials, labels and the like to enhance the appeal of these products. A large number of techniques exist for forming desired designs on a panel substrate. One of these techniques, printing, has been used to deposit a large number of small, closely spaced colored dots onto the substrate. The desired image is formed on the substrate by depositing the dots in a predetermined pattern. It has also been recognized that printed displays can be enhanced by depositing a thick layer of colored material on the substrate. Nevertheless, these known techniques in marketing suffer the same disadvantages and drawbacks that have existed in automotive display panels. 
     Since, in the automotive industry, automobile stylists and designers are continually seeking ways for differentiating a vehicle&#39;s appearance, it is an object of the present invention to provide an automotive display panel which is different in styling from existing designs. Moreover, it is an object of the present invention to avoid the aforementioned disadvantages and problems associated with existing automotive display panels. 
     SUMMARY OF THE INVENTION 
     In accordance with this invention, a display for automotive instrumentation is provided which satisfies styling and quality control requirements at competitive pricing. 
     The present automotive display panel has a metallic appearance even though the primary substrate is a plastic material. The process for making the automotive display panel begins with a plastic sheet stock. A color-tinted metallic or holographic film is deposited on the base plastic sheet. This metallic layer is applied with certain indicia, such as tick marks and digits reversed out. A layer of neutral density ink is then applied on the metallic layer to provide the indicia with a predetermined appearance. Thereafter, a chrome layer may be applied to the plastic sheet by using a process such as heat transfer or lamination. 
     After adding the chrome layer, the display will have a mirror appearance on any area where the chrome has been applied. It is desirable to provide a metallic appearance to the display with a “star burst” effect at selected areas on the display. This effect is generated by depositing finely configured lines in clear or color-tinted transparent ink. These configured lines include concentric circles, radial lines, herringbone designs or combinations of various configured lines. The depositing of very fine configured lines creates a glistening effect that is aesthetically appealing to the vehicle operator. Further, the automotive display meets the demands of vehicle users from a visibility perspective. 
     Another step in the formation of the automotive display panel includes creating a three-dimensional appearance. One technique for accomplishing this appearance is to emboss or form any desired area on the display to create the desired three-dimensional appearance. Finally, the last step of the manufacturing process for the automotive display involves cutting the display into its final desired shape. 
     In accordance with the present invention, the colors, flat metallic appearance and indicia, such as digits, are applied to the stock material by screen-printing. Silver, gold, color-tinted chrome finish and holographic finish are formed by depositing metallic or holographic film on the base stock sheet by either heat stamping or lamination. Silver, gold or tinted chrome finish can also be obtained using a metallic-based ink that is applied in the same way as other screen printing inks. As set forth previously, the “star burst” effect is created by depositing very fine configured lines in clear or color-tinted ink. 
     The present invention provides an automotive display panel with a metallic appearance using a plastic substrate material. The display panel is backlit for illuminating the information on the display panel, particularly at nighttime. If the display panel was made of metal, having a metallic appearance that appeals to vehicle users, the panel would have to be front-lit and would not be as effective because of the glare generated by the brushed metal surface. Thus, the present invention avoids the problems associated with using a metal automobile display panel while at the same time reducing weight and cost. 
    
    
     The foregoing and other advantages and features of the invention will be more apparent from the following description when taken in connection with the accompanying drawings. 
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is an illustration of an automobile display panel having a plurality of instrument dials made in accordance with the present invention. 
     FIG. 2 is an illustration of one embodiment of an automotive instrument dial or panel made in accordance with the present invention. 
     FIG. 3 is an illustration of another embodiment of an automotive instrument dial or panel made in accordance with the present invention. 
     FIG. 4 is an illustration of backlighting the automotive display panel made in accordance with the present invention. 
     FIG. 5 is a schematic view of a forming step in the process of manufacturing an automotive display panel in accordance with the present invention. 
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     FIG. 1 illustrates an automotive display panel  10  made in accordance with the present invention. As illustrated, the automotive display panel includes individual instrument dials  12 - 18 , which display information regarding speed, RPM and other information regarding a vehicle&#39;s operation. 
     FIG. 2 illustrates one of the instrument dials  16  made in accordance with the present invention. As will be described in more detail, the instrument display  16  includes a central area  20 , which is surrounded by peripheral area  22 . The third area on instrument dial  16  to be discussed includes chamfer ring  24  and mile tick marks  26 . 
     The process for making automotive display  16  begins with a plastic material sheet, which is preferably clear. In one embodiment, area  22  on display  16  is screen-printed with a layer of silver ink having mile digits and tick marks reversed out. This provides area  22  with a flat metallic appearance. Then, a layer of neutral density ink is applied to the mile digits and minor tick marks to provide them with a dark appearance during the day. Since the neutral density ink is semi-transparent, the numbers and tick marks may be backlit such as shown in FIG. 4 for nighttime visibility. 
     The process for forming area  20  may begin with a thin metal or holographic layer deposition. This provides a mirror or holographic finish. Thereafter, tinted color may be screen-printed on top of the deposited metal or a holographic layer may be applied. The latter step provides a glossy finish with a desired color or desired holographic patterns. For a different aesthetic look, a chrome layer may be applied by using a process such as heat transfer. If a chrome ink is applied by heat transfer to area  20 , the instrument display  16  will have a mirror appearance at area  20 . 
     After creating a metallic-looking finish, finely configured lines, such as fine concentric circles or radial lines, are applied to area  20  with either a clear or tinted ink for the purpose of creating a “star burst” appearance. The finely configured lines of ink may be applied to the area  20  using conventional screen-printing or offset printing. 
     After the printing is completed on the plastic substrate forming display  16 , the display may be embossed or dented at a desired area to provide a three-dimensional appearance. For example, the plane of area  20  may be displaced relative to the plane of area  22 , thereby creating the chamfer ring  24  and a multi-level appearance. 
     FIG. 5 provides a schematic representation of one way for forming the multi-level or three-dimensional appearance for display  16 . A pressure bladder  30  presses a stock sheet  32  against a forming tool  34  to obtain the desired shape. As will be apparent to those skilled in the art, the plastic stock sheet  32  includes a plurality of instrument dials or displays  16 . Similarly, the forming tool  34  includes a plurality of receptacles for receiving each area  20  from each display  16  on stock sheet  32 , thereby creating a multi-level or three-dimensional appearance for each display  16 . 
     The last step in the procedure is cutting the printed dials  16  from the stock sheet  32 . During the cutting step, any windows, such as window  36 , are cut to provide for display of, for example, the odometer. 
     FIG. 4 illustrates, schematically, the backlighting of display  16 . A light source  38 , which may include LEDs, is provided for backlighting the display  16 . If the automotive display  16  was made of metal, it would not be possible to backlight it. However, the display  16  provides a metallic appearance on a clear plastic substrate, thereby allowing it to be backlit. 
     FIG. 3 illustrates an alternative embodiment of the present invention. In this embodiment, automotive display panel  16  may be divided into areas  40 ,  42  and  44 . Area  40  is defined by the darkened surface in FIG.  3 . The horseshoe area  42  is displaced from area  40  for creating a multi-level or three-dimensional appearance. The perimeter of the horseshoe area  42  is identified as  44 . In the embodiment of the invention illustrated in FIG. 3, area  40  includes a “star burst” appearance while area  42  has a brushed metal appearance. The perimeter of the horseshoe area  42  has a glossy metallic appearance or holographic appearance for the purpose of highlighting the horseshoe area  42 . 
     The process for making the embodiment of the invention illustrated in FIG. 3 is generally similar to the process described in connection with FIG.  2 . The process begins with a clear plastic substrate. A color layer, such a blue, is then printed on the substrate with the kilometer numbers, tick marks and areas  42  and  44  reversed out. This creates the area which is identified in FIG. 3 as  40 . 
     Thereafter, a chrome ink layer is printed on the substrate with the mile numbers and tick marks reversed out. The chrome ink layer forms the area which is identified in FIG. 3 as  42 . A layer of neutral density ink is deposited behind the hollow mile numbers and tick marks in area  42  to provide a dark appearance during the day, which can be backlit at night. A layer of white translucent ink is then deposited behind the kilometer numbers and tick marks in area  40  to provide a light appearance during the day and a translucent surface for being backlit at night. 
     Subsequent to the preceding steps, a dark layer of ink is placed over the entire surface area of display  16 , except at the numbers and tick marks for mile and kilometer designations. This provides an opaque appearance for the surface area. 
     The next step in the process is to generate a brushed metal appearance in area  42 . Finely configured lines in the form of concentric circles, for example, are printed on area  42  in lightly neutral density ink using screen-printing. This provides an appearance similar to brushed metal. The desired appearance can also be achieved by combining configured lines. For example, the concentric circles may be deposited on finely applied linear lines to create the simulation of brushed metal. 
     A glossy metallic foil or holographic foil can thereafter be deposited on the perimeter  44  of the horseshoe area  42 . After the deposition of the foil, finely configured lines, such as concentric circles or radial lines, are printed on area  40  to create the “star burst” appearance as previously described. 
     After the printing is completed, the display  16 , illustrated in FIG. 3, is embossed for creating a three-dimensional appearance at area  42 . Finally, the instrument dial display  16  is cut from the stock sheet  32  and the display window  36  is similarly cut away. 
     Silver, gold or other color-tinted chrome ink finishes and holographic finishes may be created by depositing metallic or holographic film on the clear plastic base sheet. The areas having a metallic appearance, digits or color are formed by conventional screen-printing. As described previously, the “star burst” appearance is generated by depositing finely configured lines, such as concentric circles or radial lines, on the surface in clear or color-tinted transparent ink. This may be accomplished by conventional screen-printing or offset printing. For the purposes of the present invention, a holographic film of any type known in the pertinent art may be used in the areas identified as  20  in FIG. 2 and 40 in FIG.  3 . If holographic film is applied to the clear plastic substrate, the backlit appearance would provide another “look” that could be used in addition to, or instead of, the previously described metallic appearance. 
     It is to be understood that the above-described embodiments are merely illustrative of the principles of the present invention. Other embodiments can be devised by those skilled in the art without departing from the scope of the invention.