WO2024102888A1

WO2024102888A1 - Method of forming barcklit vehicle panels on a polymer substrate

Info

Publication number: WO2024102888A1
Application number: PCT/US2023/079196
Authority: WO
Inventors: Daniel Vander Sluis; Mark T. PILETTE; Benjamin J. BARBER; Michael Wurster; Thomas Paule; Oliver Pace
Original assignee: Magna Exteriors Inc.
Priority date: 2022-11-10
Filing date: 2023-11-09
Publication date: 2024-05-16

Abstract

A vehicle panel that has a first appearance during the daylight but is capable of being backlight in a dark environment causing the badge to have a second appearance as light is transmitted through micro-apertures formed through the vehicle panel. The vehicle panel is such that the micro-apertures a not visible in the first appearance due to their small size, which is created using laser ablation, screen printing or digital printing techniques.

Description

METHOD OF FORMING BARCKLIT VEHICLE PANELS ON A POLYMER

SUBSTRATE

FIELD OF THE INVENTION

The present invention relates to forming backlit vehicle panels using laser ablation and digital printing techniques.

BACKGROUND OF THE INVENTION

In the field of automotive design improvements in lighting units have made it possible to expand the aesthetics of the automobile. One area where improvements are possible is having different panels including doors, badges or emblems, and sub-panels employed on vehicle. In particular it is desirable to provide an article that when viewed in daylight looks like a typical non-illuminate article, but in a dark environment the article is connected to a light unit or informational display that illuminates the article. Another area of expanding automobile aesthetics involves the formation of large graphics on painted polymer substrates, which can be colored a different color or optionally be backlit. Forming large graphics on painted polymer substrates using laser ablation is challenging because the substrate can be damaged during the light during the laser ablation process. Another area of expanding automobile aesthetics is to further enhance information communication by providing an article that is backlit by a screen that provides information.

SUMMARY OF THE INVENTION A backlit vehicle panel having a display panel having light emitting surface that projects light and one or more sensors on the display panel that project light. The arrangement further includes a panel body connected to the light emitting surface of the display panel and the one or more sensors. The panel body is formed of layers of materials that include a polymer substrate having an appearance side and a painted side, wherein the paint side receives light from the light emitting surface of the display panel, which is then projected from the appearance side. The panel body is transparent and allows the light from the light source to pass through the panel body and project from the appearance side. The layers of materials further include a sacrificial material layer adjacent the painted side of the polymer substrate. There is also at least one base paint layer of the layers of materials over the sacrificial material layer.

The backlit vehicle panel also includes an ablation zone, where the at least one base paint layer and a portion of the sacrificial material layer have been removed, wherein at least a portion of the light emitting surface of the display panel aligns with the ablation zone. When the light emitting surface of the display panel is off, the display panel is not visible through the appearance side of the panel body. When the light emitting surface is on, the light emitting surface is on and projecting the light, the light emitting surface is visible through the appearance side of the display panel. Also, when the one or more sensors of the display panel is off, the one or more sensors are not visible through the appearance side of the panel body. When the one or more sensors is on and projecting light, the one or more sensors are visible through the appearance side of the display panel. Further areas of applicability of the present invention will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples, while indicating the preferred embodiment of the invention, are intended for purposes of illustration only and are not intended to limit the scope of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention will become more fully understood from the detailed description and the accompanying drawings, wherein:

Fig. 1 is top front side perspective view of a vehicle with a plurality of backlit vehicle panels according to one embodiment of the invention.

Fig. 2 is top rear side perspective view of a vehicle with a plurality of backlit vehicle panels according to one embodiment of the invention.

Fig. 3A a schematic front plan view of a backlit vehicle panel.

Fig. 3B is a schematic rear perspective view of the backlit vehicle panel.

Fig. 4A is a front side perspective view of an alternate embodiment of the invention of a backlit vehicle panel having a Q Dot display unit.

Fig. 4B is an exploded view front side perspective view of an alternate embodiment of the invention of a backlit vehicle panel having a Q Dot display unit.

Fig. 5A is a cross-sectional side perspective view of a method of laser ablation to form a backlit vehicle panel according to one embodiment of the invention.

Fig. 5B is a cross-sectional side perspective view of the backlit vehicle panel formed using the method shown in Fig. 5A. Fig. 6A is a cross-sectional side perspective view of a method of laser ablation to form a backlit vehicle panel according to another embodiment of the invention.

Fig. 6B is a cross-sectional side perspective view of the backlit vehicle panel formed using the method shown in Fig. 6A.

Fig. 7A is a cross-sectional side perspective view of a method of laser ablation to form a backlit vehicle panel according to another embodiment of the invention.

Fig. 7B is a cross-sectional side perspective view of the backlit vehicle panel formed using the method shown in Fig. 7A.

Fig. 8A is a cross-sectional side perspective view of a method of laser ablation to form a backlit vehicle panel according to another embodiment of the invention.

Fig. 8B is a cross-sectional side perspective view of the backlit vehicle panel formed using the method shown in Fig. 8A.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The following description of the preferred embodiments is merely exemplary in nature and is in no way intended to limit the invention, its application, or uses.

Referring now to Figs. 1 and 2 the present invention is directed to an arrangement and method of making backlit vehicle panels 700 a-i on a polymer substrate. Each of the backlit vehicle panels 770 a-i is any trim piece that is connectable to a vehicle exterior surface, with specific applications described below, but are not intended to limit the scope of the invention. It is also within the scope of this invention for the backlit vehicle panels 700 a-i to be attached to interior surfaces in the vehicle cabin, storage compartments or engine compartments depending on the needs of a particular application. Fig. 1 shows examples where backlit vehicle panels 700a, 700b, 700c are respective A-pillar trim piece, B-pillar trim piece, C-pillar trim piece, and backlit vehicle panel 700d is a trim piece connectected to a fender 704 on a vehicle 702. Fig. 2 shows the front of the vehicle 702 with backlit vehicle panels 700e, 700f trim pieces as part of a front fascia 706 and a hood 708 of the vehicle 702. Also shown is a backlit vehicle panel 700g connected as a trim piece to a side door 710 of the vehicle. Fig. 14 shows the rear of a vehicle 702‘ witha backlit vehicle panel 700h being a trim panel connected to a rear liftgate 712. The vehicle 702' is also an electric vehicle that has a charge port 714 with a backlit vehicle panel 700i is trim piece for a charge port, located adjacent the charge port. The backlit vehicle panel 700i displays information messages pertaining to a battery status of the vehicle are displayed on the light emitting surface the charge status of the vehicle 702‘. The backlit vehicle panels 700a-i are used to display vehicle informaton on the outside of the vehicle in areas that are typically painted with body color. The backlit vehicle panels 700 a-i include any other static or moveable exterior or interior trim part that gets a secondary function by displaying information about the vehicle, e.g. charging state, entertainment system information and commands, logos or just decorative designs. The information is only displayed, when desired, which means that the areas of the information display are not recognizable when switched off (i.e. , hidden until lit). The hidden until lit features are achieved by using various methods that include laser ablation, digital printing, and the use of argent layers with micro-apertures, which are described in greater detail below.

Referring now to Figs. 3A and 3B specific features of the backlit vehicle panels 700 a-i will now be discussed. The backlit vehicle panels 700 a-i are each include a display unit 716 that is connected to a carrier 718 or bonded to a rear side 720 of the backlit vehicle panels 700 a-i. The carrier 718 is connected to a vehicle parts and includes mechanical lock features, such as snap tangs that grasp the display unit 716. Each display unit 716 has a display surface 722 that is positioned behind the rear side 720 and is hidden until lit. The display surface 722 is used to convey messages, graphics or different light through laser ablated designs depending on the intended function. The display surface 722 can be used for aesthetics or can serve a funcitonal purpose such as displaying charge information, radio or media controls, window and door control options, text messages or motion pictures. It is also within the scope of the invention for the display surface 722 to include one or more sensors 724 that can be buttons or scroll bars that allow a user to interact with the information on the display surface 722. The sensors 724 can be physical buttons that extend throught the surface of the rear side 720, or they can be touch sensors with haptic feedback that provides the user with a vibration when the sensor is touched.

Referring now to Figs. 4A and 4B an alternate embodiment of the invention of a vehicle pillar 726 which is a backlit vehicle panel. The vehicle pillar 726 is shown in conjunction with a Q Dot disply unit 728. While a vehicle pillar 726 is shown it is within the scope of this invention for the Q Dot display unit 728 to be implemented in any type of display including all of the backlit vehicle panels 700 a-i, 524, 554, 582 discused above or below. A Q Dot display unit 728 utilizes color ultraviolet light waves that are emitted from ultraviolet (UV) LED light sources 730 that are connected to a Light source carrier 732. The light from the UV LED light sources 730 is passed through filters 734 and then a diffusive film 736 that spreads the light ouput prior to being emitted through layers of materials 738 formed using the methods described for the backlit vehicle panels 700 a-i, 524, 554, 582 discused above or below. The layers of materials 738 have been painted and undergone paint removal forming an ablation zone 740. A layer carrier 742 holds the Light source carrier 732 with UV light sources 730, filters 734 and diffusive film 736. The layer carrier 742 is then connected to the back side of the vehicle pillar 726 and the layers of material 738 using adhesives, infrared welding or mechanical fasteners. In operation light from the ultraviolet LED light sources 730 is passed through one or more of the filters 734 that function as a substrate that allows color conversion of ultraviolet light to visible colors that are sharp and vibrant in color. The light is then spread out by the diffusive film 736 and then passes onto the ablation zone 740 of the layers of materials 738 to provide sharp colored light output thorough the ablation zone 740. The light can be used to back light graphics that have been created in the ablation zone 740 or they can be used to display information, such as radio/media and lighting controls, door and window controls, etc.

Figs. 5A and 5B are schematic diagrams showing an enlarged cross-sectional view of the formation of the backlit vehicle panels 700 a-i (shown in Fig. 5B), which are formed by a number of material layers using a method 500 of laser ablation that will be described herein. The backlit vehicle panels 700 a-i are formed by first preparing a layers of material 501 which include a polymer substrate 502 having an appearance side 504 and a painted side 506. The polymer substrate 502 is made of any type of transparent, semitransparent or opaque polymer material. In a preferred embodiment of the invention the polymer substrate 502 is polycarbonate or poly(methyl methacrylate) (also referred to hereafter as PMMA). To the appearance side 504 of the polymer substrate 502 is a hard coat layer 510 of hard coat material is applied. The hard coat layer 510 is a type of material that protects the polymer substrate 502 and includes suitable materials known for hardness and durability, such as styrene maleic anhydride, silica or other suitable materials.

On the painted side 506 of the polymer substrate 502 is a sacrificial material layer 508. The sacrificial material layer 508 is a transparent paint layer that protects the polymer substrate 502 from damage from the ablation laser during the ablation process. The sacrificial material layer 508 is formed with many types of paint and it is within the scope of this invention for the paint to be water based or solvent based. While the sacrificial material layer 508 is shown as a single layer is described within the scope of the invention for there to be multiple layers since it may be necessary to apply several coats or layers to achieve a desired thickness. The sacrificial material layer 508 is generally at least 9 microns in thickness, preferably at least about 10 microns in thickness, and ideally 10 microns in thickness.

The method 500 further includes providing at least one base paint layer 512 onto the sacrificial material layer. While a single layer is described within the scope of the invention for there to be multiple layers since it may be necessary to apply several coats or layers to achieve a desired thickness. The base paint layer 512 can be a shaded paint that is grayscale or a color layer. When grayscale is used the base paint layer 512 is black, gray or white and is generally greater than about 12 microns thickness, preferably less than about 15 microns thickness or ideally 12 to 15 microns in thickness. The shaded paint can be formed with many types of paint. It is within the scope of this invention for the paint to be water based or solvent based. When the base paint layer 512 is a colored layer it will typically require a greater thickness to provide sufficient color coverage, such as generally greater than about 22 microns thickness, preferably less than about 28 microns thickness or ideally 22 to 28 microns in thickness.

The method 500 also includes applying a primer layer 514 to the painted side and providing an ablation zone 516 that will be ablated using a laser 520 that will be described in greater detail below. The primer layer 514 is a topcoat opaque paint layer that helps adhesion of a successively applied accent layer 518 to the layers of material 501 after being ablated by the laser 520. The primer layer 514 is generally greater than about 15 microns thickness but can be less than or equal to 15 microns thickness or ideally about 15 microns in thickness. While a single layer is described within the scope of the invention for there to be multiple layers since it may be necessary to apply several coats or layers to achieve a desired thickness.

The method 500 includes providing the laser 520 for selectively emitting an ablation laser 522 or laser beam onto the ablation zone 516 on the painted side 506 of the polymer substrate 502. The ablation laser 522 removes select portions of the base paint layer 512, the primer layer 514 and a portion of the sacrificial material layer 508. The ablation zone 516 is an area on the finished article 501 where it is desirable to remove the base paint layer 512, the primer layer 514 and a portion of the sacrificial material layer 508 using ablation laser 522 to bum or remove the primer layer 514, the base paint layer 512 and a portion of the sacrificial material layer 508. Since the intensity of the ablation laser 522 can damage the polymer substrate 502 the present invention’s use of the sacrificial material layer 508 protects the polymer substrate 502 by providing a protective layer than can be ablated and prevents damage to the polymer substrate 502. The ablation zone 516 can have a certain design or pattern in order to form letters, logos or decorative patterns depending on the desired aesthetic. In the embodiment shown in Fig. 5B the ablation zone 516 is a large area or window and the display panel 716 is positioned so that the display surface 722 and one or more sensors 724 of the display panel 716 are positioned within the ablation zone 516. When not illuminated the display surface 722 and one or more sensors 724 are not visible though the partially ablated sacrificial material layer 508 and optional hard coat layer 510. However, once illuminated the rays of light from the display surface 722 and one or more sensors 724 are visible through the partially ablated sacrificial material layer 508, polymer substrate 502 and optional hard coat layer 510.

The type of and intensity of ablation laser 522 used will depend on many factors, with one main factor being the thickness of the base paint layer 512 and the primer layer 514. Also, the color of the different layers can have a significant affect. The color is an important factor because the amount of energy required to remove layers in the ablation zone 516 can vary due to color, which changes the energy absorption of the paint material in the ablation zone 516. As a result, the ablation laser 522 can have a different and specific wattage value, pulse time, and wavelength depending on the color of the base paint layer 512, and primer layer 514.

After operation of the laser 520, the accent layer 518 is applied onto the painted side 506 and ablation zone 516 of the polymer substrate 502. The accent layer 518 is a color paint layer that can have any desired color of shade that will help to accent the ablation zone 516 to create the desired aesthetic look of the finished article 501 . The accent layer can be formed with many types of paint. It is within the scope of this invention for the paint to be water based or solvent based. The accent layer is preferably a color paint but can be white or any color that would be in contrast to the base layer. The accent layer can be transparent, but does not need to be, however, a translucent level of 20% or higher is optimum in applications where backlighting is used. The accent layer 518 can be paint used to fill in or accent the ablation zone 516 or it can be an opaque layer that can then be backlit for a desired appearance. The accent layer 518 is generally greater than about 25 microns thickness, preferably less than about 30 microns thickness or ideally 25 to 30 microns in thickness. A single layer is described however it is within the scope of the invention for there to be multiple layers since it may be necessary to apply several coats or layers to achieve a desired thickness. During final assembly, the display panel 716 is connected to the accent layer 518 so that the rays of light from the display surface 722 and one or more sensors 724 pass through the accent layer 518. It is also within the scope of this invention for the display panel 716 to be a Q Dot display unit similar to the Q Dot display unit 728 described in Figs. 4A and 4B above.

Figs. 6A and 6B are schematic diagrams showing an enlarged cross-sectional view of a method 525 of forming a backlit vehicle panel 524, which is an alternate construction that can be used in place of backlit panels 700 a-i (shown in Fig. 6B). In this embodiment of the invention the backlit panel 524 formed by first preparing a layers of material 526 which include a polymer substrate 528 having an appearance side 530 and a painted side 532. The polymer substrate 528 is made of any type of transparent, semi-transparent or opaque polymer material. In a preferred embodiment of the invention the polymer substrate 528 is polycarbonate or poly(methyl methacrylate) (also referred to hereafter as PMMA). To the appearance side 530 of the polymer substrate 528 is a hard coat layer 534 of hard coat material is applied. The hard coat layer 534 is a type of material that protects the polymer substrate 528 and includes suitable materials known for hardness and durability, such as styrene maleic anhydride, silica or other suitable materials.

On the painted side 532 of the polymer substrate 528 is a sacrificial material layer 536. The sacrificial material layer 536 is a transparent paint layer that protects the polymer substrate 528 from damage from the ablation laser during the ablation process. The sacrificial material layer 536 is formed with many types of paint and it is within the scope of this invention for the paint to be water based or solvent based. While the sacrificial material layer 536 is shown as a single layer is described within the scope of the invention for there to be multiple layers since it may be necessary to apply several coats or layers to achieve a desired thickness. The sacrificial material layer 536 is generally at least 9 microns in thickness, preferably at least about 10 microns in thickness, and ideally 10 microns in thickness.

The method 525 further includes providing at least one base paint layer 538 onto the sacrificial material layer 536. While a single layer is described within the scope of the invention for there to be multiple layers since it may be necessary to apply several coats or layers to achieve a desired thickness. The base paint layer 538 can be a shaded paint that is grayscale or a color layer. When grayscale is used the base paint layer 538 is black, gray or white and is generally greater than about 12 microns thickness, preferably less than about 15 microns thickness or ideally 12 to 15 microns in thickness. The shaded paint can be formed with many types of paint. It is within the scope of this invention for the paint to be water based or solvent based. When the base paint layer 538 is a colored layer it will typically require a greater thickness to provide sufficient color coverage, such as generally greater than about 22 microns thickness, preferably less than about 28 microns thickness or ideally 22 to 28 microns in thickness.

The method 525 also includes applying a primer layer 540 to the painted side and providing an ablation zone 542 that will be ablated using a laser 544 that will be described in greater detail below. The primer layer 540 is a topcoat opaque paint layer that helps adhesion of a successively applied accent layer 550 to the layers of material 526 after being ablated by the laser 544. The primer layer 540 is generally greater than about 15 microns thickness but can be less than or equal to 15 microns thickness or ideally about 15 microns in thickness. While a single layer is described within the scope of the invention for there to be multiple layers since it may be necessary to apply several coats or layers to achieve a desired thickness.

The method 525 includes providing the laser 544 for selectively emitting an ablation laser 546 or laser beam onto the ablation zone 542 on the painted side 532 of the polymer substrate 528. The ablation laser 544 removes select portions (i.e. , the ablation zone 542) the base paint layer 538, the primer layer 540 and a portion of the sacrificial material layer 536. In the present embodiment of the invention the ablation laser 546 is emitted from the laser 544 at an angle A in order to create an angled light passage 548. The angle A shown is approximately 45 degrees to the surface of the layers of materials 526, however, it is within the scope of the invention for any suitable angle to be used, including a 10 degree angle, 20 degree angle, 30 degree angle and 40 degree angle.

Since the intensity of the ablation laser 546 can damage the polymer substrate 528 the present invention’s use of the sacrificial material layer 536 protects the polymer substrate 528 by providing a protective layer than can be ablated and prevents damage to the polymer substrate 528. The ablation zone 542 can have a certain design or pattern in order to form letters, logos or decorative patterns depending on the desired aesthetic. In the embodiment shown in Fig. 6B the ablation zone 542 is an angled light passage 548 where a display panel 716’ is positioned so that a display surface 722’ and one or more sensors 724’ of the display panel 716’ are positioned in relation the ablation zone 542 to emit rays of light through the angled light passage 548. When not illuminated the display surface 722’ and one or more sensors 724’ are not visible though the partially ablated sacrificial material layer 536 and optional hard coat layer 534. However, once illuminated the rays of light from the display surface 722’ and one or more sensors 724’ are visible through the partially ablated sacrificial material layer 536, polymers substrate 528 and optional hard coat layer 534.

The type of and intensity of ablation laser 546 used will depend on many factors, with one main factor being the thickness of the base paint layer 538 and the primer layer 540. Also, the color of the different layers can have a significant affect. The color is an important factor because the amount of energy required to remove layers in the ablation zone 546 can vary due to color, which changes the energy absorption of the paint material in the ablation zone 542. As a result, the ablation laser 546 can have a different and specific wattage value, pulse time, and wavelength depending on the color of the base paint layer 538, and primer layer 540.

After operation of the laser 544, the accent layer 550 is applied onto the painted side 532 and ablation zone 542. The accent layer 550 is a color paint layer that can have any desired color of shade that will help to accent the ablation zone 542 to create the desired aesthetic look of the finished article 526. The accent layer can be formed with many types of paint. It is within the scope of this invention for the paint to be water based or solvent based. The accent layer is preferably a color paint but can be white or any color that would be in contrast to the base layer. The accent layer can be transparent, but does not need to be, however, a translucent level of 20% or higher is optimum in applications where backlighting is used. The accent layer 550 can be paint used to fill in or accent the ablation zone 516 or it can be an opaque layer that can then be backlit for a desired appearance. The accent layer 550 is generally greater than about 25 microns thickness, preferably less than about 30 microns thickness or ideally 25 to 30 microns in thickness. A single layer is described however it is within the scope of the invention for there to be multiple layers since it may be necessary to apply several coats or layers to achieve a desired thickness. During final assembly the display panel 716’ is connected to the accent layer 550 so that the rays of light from the display surface 722’ and one or more sensors 724’ pass through the accent layer 536 via the angled light passage 548. The display panel 716’ is identical to the display panel 716 used in other embodiments. It is also within the scope of this invention for the display panel 716’ to be a Q Dot display unit similar to the Q Dot display unit 728 described in Figs. 4A and 4B above.

Figs. 7A and 7B are schematic diagrams showing an enlarged cross-sectional view of a method 552 of forming a backlit vehicle panel 554, which is an alternate construction that can be used in place of backlit panels 700 a-i (shown in Fig. 6B) and backlit panel 524 (Fig. 6B). In this embodiment of the invention the backlit panel 554 formed by first preparing a layers of material 556 which include a polymer substrate 558 having an appearance side 560 and a painted side 562. The polymer substrate 558 is made of any type of transparent, semi-transparent or opaque polymer material. In a preferred embodiment of the invention the polymer substrate 558 is polycarbonate or poly(methyl methacrylate) (also referred to hereafter as PMMA). To the appearance side 560 of the polymer substrate 558 is a hard coat layer 564 of hard coat material is applied. The hard coat layer 564 is a type of material that protects the polymer substrate 558 and includes suitable materials known for hardness and durability, such as styrene maleic anhydride, silica or other suitable materials.

On the painted side 562 of the polymer substrate 558 is a sacrificial material layer 566. The sacrificial material layer 566 is a transparent paint layer that protects the polymer substrate 558 from damage from the ablation laser during the ablation process. The sacrificial material layer 566 is formed with many types of paint and it is within the scope of this invention for the paint to be water based or solvent based. While the sacrificial material layer 566 is shown as a single layer is described within the scope of the invention for there to be multiple layers since it may be necessary to apply several coats or layers to achieve a desired thickness. The sacrificial material layer 566 is generally at least 9 microns in thickness, preferably at least about 10 microns in thickness, and ideally 10 microns in thickness.

The method 552 further includes providing at least one base paint layer 568 onto the sacrificial material layer 566. While a single layer is described within the scope of the invention for there to be multiple layers since it may be necessary to apply several coats or layers to achieve a desired thickness. The base paint layer 568 can be a shaded paint that is grayscale or a color layer. When grayscale is used the base paint layer 568 is black, gray or white and is generally greater than about 12 microns thickness, preferably less than about 15 microns thickness or ideally 12 to 15 microns in thickness. The shaded paint can be formed with many types of paint. It is within the scope of this invention for the paint to be water based or solvent based. When the base paint layer 568 is a colored layer it will typically require a greater thickness to provide sufficient color coverage, such as generally greater than about 22 microns thickness, preferably less than about 28 microns thickness or ideally 22 to 28 microns in thickness.

The method 552 also includes applying a primer layer 570 to the painted side and providing a plurality of ablation zones 572a, 572b, 572c. While three ablation zones are shown, it is within the scope of this invention for there to be a greater or lesser number of ablation zones depending on the needs of a particular application. Each ablation zone 572a, 572b, 572c is formed using a lasers 574a, 574b 574c which is three separate lasers as show or it can be a single laser that moves to each location. The primer layer 570 is a topcoat opaque paint layer that helps adhesion of a successively applied accent layer 576 to the layers of material 556 after being ablated by the lasers 574a, 574b 574c. The primer layer 570 is generally greater than about 15 microns thickness but can be less than or equal to 15 microns thickness or ideally about 15 microns in thickness. While a single layer is described within the scope of the invention for there to be multiple layers since it may be necessary to apply several coats or layers to achieve a desired thickness.

The method 552 includes providing the lasers 574a, 574b 574c each for selectively emitting an ablation laser 578a, 578b, 578c or laser beam onto the ablation zone 572a, 572b, 572c on the painted side 562 of the polymer substrate 558. The ablation laser 578a, 578b, 578c removes select portions of (i.e., the ablation zone 572a, 572b, 572c) the base paint layer 568, the primer layer 570 and a portion of the sacrificial material layer 566. In the present embodiment of the invention the ablation laser 578a, 578b, 578c is emitted from the lasers 574a, 574b 574c to create three separate ablation zones 572a, 572b, 572c.

Since the intensity of the ablation laser 578a, 578b, 578c can damage the polymer substrate 558 the present invention’s use of the sacrificial material layer 566 protects the polymer substrate 558 by providing a protective layer than can be ablated and prevents damage to the polymer substrate 558. The ablation zone 572a, 572b, 572c can have a certain design or pattern in order to form letters, logos or decorative patterns depending on the desired aesthetic. In the embodiment shown in Fig. 7B the ablation zone 572a, 572b, 572c is a light passage where a display panel 716” is positioned so that a display surface 722” and one or more sensors 724” of the display panel 716” are positioned in relation the ablation zone 572a, 572b, 572c to emit rays of light through the light passage. When not illuminated the display surface 722” and one or more sensors 724” are not visible though the partially ablated sacrificial material layer 566 and optional hard coat layer 564. However, once illuminated the rays of light from the display surface 722” and one or more sensors 724” are visible through the partially ablated sacrificial material layer 566, polymer substrate 558 and optional hard coat layer 564.

The type of and intensity of ablation laser 578a, 578b, 578c used will depend on many factors, with one main factor being the thickness of the base paint layer 568 and the primer layer 570. Also, the color of the different layers can have a significant affect. The color is an important factor because the amount of energy required to remove layers in the ablation zone 572a, 572b, 572c can vary due to color, which changes the energy absorption of the paint material in the ablation zone 572a, 572b, 572c. As a result, the ablation laser 578a, 578b, 578c can have a different and specific wattage value, pulse time, and wavelength depending on the color of the base paint layer 568, and primer layer 570.

After operation of the lasers 574a, 574b 574c, the accent layer 576 is applied onto the painted side 562 and each ablation zone 572a, 572b, 572c. The accent layer 576 is a color paint layer that can have any desired color of shade that will help to accent each ablation zone 572a, 572b, 572c to create the desired aesthetic look of the finished article 554. The accent layer can be formed with many types of paint. It is within the scope of this invention for the paint to be water based or solvent based. The accent layer is preferably a color paint but can be white or any color that would be in contrast to the base layer. The accent layer can be transparent, but does not need to be, however, a translucent level of 20% or higher is optimum in applications where backlighting is used. The accent layer 576 can be paint that is used to fill in or accent each ablation zone 572a, 572b, 572c or it can be an opaque layer that can then be backlit for a desired appearance. The accent layer 576 is generally greater than about 25 microns thickness, preferably less than about 30 microns thickness or ideally 25 to 30 microns in thickness. A single layer is described however it is within the scope of the invention for there to be multiple layers since it may be necessary to apply several coats or layers to achieve a desired thickness. During final assembly, the display panel 716” is connected to the accent layer 576 so that the rays of light from the display surface 722” and one or more sensors 724” pass through the accent layer 536 via the angled light passage 548. The display panel 716” is identical to the display panel 716 used in other embodiments. It is also within the scope of this invention for the display panel 716” to be a Q Dot display unit similar to the Q Dot display unit 728 described in Figs. 4A and 4B above.

Figs. 8A and 8B are schematic diagrams showing an enlarged cross-sectional view of an alternate method 580 of forming a backlit vehicle panel 582, which is an alternate construction that can be used in place of backlit panels 700 a-i (shown in Fig. 6B), backlit panel 524 (Fig. 6B) and backlit vehicle panel 554 (Fig. 7B). In this embodiment of the invention the backlit panel 582 formed by first preparing a layers of material 584 which include a polymer substrate 586 having a painted side 588 that is also the appearance side. In contrast with Figs. 7A and 7B the layers of materials 584 are applied to the appearance side or show side of the backlit vehicle panel 582. The polymer substrate 586 is made of any type of transparent, semi-transparent or opaque polymer material. In a preferred embodiment of the invention the polymer substrate 586 is polycarbonate or poly(methyl methacrylate) (also referred to hereafter as PMMA). To the painted side 588 of the polymer substrate 586 is a hard coat layer 590 of hard coat material is applied. The hard coat layer 590 is a type of material that protects the polymer substrate 586 and includes suitable materials known for hardness and durability, such as styrene maleic anhydride, silica or other suitable materials.

On the painted side 588 of the polymer substrate 586 is a sacrificial material layer 592. The sacrificial material layer 592 is a transparent paint layer that protects the polymer substrate 586 from damage from the ablation laser during the ablation process. The sacrificial material layer 592 is formed with many types of paint and it is within the scope of this invention for the paint to be water based or solvent based. While the sacrificial material layer 592 is shown as a single layer is described within the scope of the invention for there to be multiple layers since it may be necessary to apply several coats or layers to achieve a desired thickness. The sacrificial material layer 592 is generally at least 9 microns in thickness, preferably at least about 10 microns in thickness, and ideally 10 microns in thickness.

The method 580 also includes applying a primer layer 594 to the painted side 588 of the polymer substrate 586. The primer layer 594 is generally greater than about 15 microns thickness but can be less than or equal to 15 microns thickness or ideally about 15 microns in thickness. While a single layer is described within the scope of the invention for there to be multiple layers since it may be necessary to apply several coats or layers to achieve a desired thickness. The primer layer 594 is an opaque paint layer that helps adhesion of a successively a base paint layer 596 to the layers of material 584. The at least one base paint layer 596 is applied onto the primer layer 594. While a single layer is described within the scope of the invention for there to be multiple layers since it may be necessary to apply several coats or layers to achieve a desired thickness. The base paint layer 596 can be a shaded paint that is grayscale or a color layer. When grayscale is used the base paint layer 596 is black, gray or white and is generally greater than about 12 microns thickness, preferably less than about 15 microns thickness or ideally 12 to 15 microns in thickness. The shaded paint can be formed with many types of paint. It is within the scope of this invention for the paint to be water based or solvent based. When the base paint layer 596 is a colored layer it will typically require a greater thickness to provide sufficient color coverage, such as generally greater than about 22 microns thickness, preferably less than about 28 microns thickness or ideally 22 to 28 microns in thickness. Figs. 8A and 8B further include providing a plurality of ablation zones 598a, 598b, 598c. While three ablation zones are shown, it is within the scope of this invention for there to be a greater or lesser number of ablation zones depending on the needs of a particular application. Each ablation zone 598a, 598b, 598c is formed using a lasers 600a, 600b 600c which is three separate lasers as shown or it can be a single laser that moves to each location.

The method 580 includes providing the lasers 600a, 600b 600c each for selectively emitting an ablation laser 602a, 602b, 602c or laser beam onto the ablation zone 598a, 598b, 598c on the painted side 588 of the polymer substrate 586. The ablation laser 602a, 602b, 602c removes select portions of (i.e., the ablation zone 598a, 598b, 598c) the base paint layer 596, the primer layer 594 and a portion of the sacrificial material layer 592. In the present embodiment of the invention the ablation laser 602a, 602b, 602c is emitted from the lasers 600a, 600b 600c to create three separate ablation zones 598a, 598b, 598c.

Since the intensity of the ablation laser 602a, 602b, 602c can damage the polymer substrate 586 the present invention’s use of the sacrificial material layer 592 protects the polymer substrate 586 by providing a protective layer than can be ablated and prevents damage to the polymer substrate 586. The ablation zone 598a, 598b, 598c can have a certain design or pattern in order to form letters, logos or decorative patterns depending on the desired aesthetic. In the embodiment shown in Fig. 8B the ablation zone 598a, 598b, 598c is a light passage where a display panel 716’” is positioned so that a display surface 722’” and one or more sensors 724’” of the display panel 716’” are positioned in relation the ablation zone 598a, 598b, 598c to emit rays of light through the light passage. When not illuminated the display surface 722”’ and one or more sensors 724”’ are not visible though the partially ablated sacrificial material layer 592 and optional hard coat layer 590. However, once illuminated the rays of light from the display surface 722’” and one or more sensors 724’” are visible through the partially ablated sacrificial material layer 592, polymer substrate 586 and optional hard coat layer 590.

The type of and intensity of ablation laser 602a, 602b, 602c used will depend on many factors, with one main factor being the thickness of the base paint layer 596 and the primer layer 594. Also, the color of the different layers can have a significant affect. The color is an important factor because the amount of energy required to remove layers in the ablation zone 598a, 598b, 598c can vary due to color, which changes the energy absorption of the paint material in the ablation zone 598a, 598b, 598c. As a result, the ablation laser 602a, 602b, 602c can have a different and specific wattage value, pulse time, and wavelength depending on the color of the base paint layer 596, and primer layer 594.

After operation of the lasers 600a, 600b 600c, the accent layer 590 is applied onto the painted side 588 and each ablation zone 598a, 598b, 598c. The accent layer 590 is a color paint layer that can have any desired color of shade that will help to accent each ablation zone 598a, 598b, 598c to create the desired aesthetic look of the finished article 582. The accent layer can be formed with many types of paint. It is within the scope of this invention for the paint to be water based or solvent based. The accent layer is preferably a color paint but can be white or any color that would be in contrast to the base layer. The accent layer can be transparent, but does not need to be, however, a translucent level of 20% or higher is optimum in applications where backlighting is used. The accent layer 590 can be paint used to fill in or accent each ablation zone 598a, 598b, 598c or it can be an opaque layer that can then be backlit for a desired appearance. The accent layer 590 is generally greater than about 25 microns thickness, preferably less than about 30 microns thickness or ideally 25 to 30 microns in thickness. A single layer is described however it is within the scope of the invention for there to be multiple layers since it may be necessary to apply several coats or layers to achieve a desired thickness. During final assembly, the display panel 716”’ is connected to the accent layer 590 so that the rays of light from the display surface 722” and one or more sensors 724”’ pass through the accent layer 536 via the angled light passage 548. The display panel 716”’ is identical to the display panel 716 used in other embodiments. It is also within the scope of this invention for the display panel 716’” to be a Q Dot display unit similar to the Q Dot display unit 728 described in Figs. 4A and 4B above.

In each of the embodiments described in Figs. 5A, 5B, 6A, 6B, 7A, 7B, 8A, 8B the light transmission of the paint is realized by laser ablation. Here, small painted areas are being ablated in a dot/hole pattern. The ablated dots/holes normally have a diameter of 100pm (+/-50pm) but can also be designed larger to increase light transmission. The visibility of the ablation, as well as the light transmission, can be changed by the pitch of the individual ablation as well as the dot pattern itself. The substrate on which the paint is applied is a translucent or transparent material. The lay-up of the paint for removal consists of at least 2 layers, but generally of 3 layers. The lowest of these forms a lighttight layer to prevent any unwanted transmission. If this layer can already be dyed in body color (mono-coat), another layer of basecoat for coloring is not necessary. As a rule, however, this first layer is a primer on which a basecoat is applied for body coloring. In addition, a layer of transparent lacquer can now be applied for sealing, but not necessarily. After applying these layers, laser removal is carried out and then the component is coated again with a layer of transparent/translucent clearcoat to protect also the lasered areas. The ablation pattern can be arranged in various shapes so that e.g., digital numbers, letters, level bars, logos or other things can be displayed. In addition to dot ablation, the paint can also be fully removed to create increased transmission and better visibility of the information displayed on the light source/display behind or to highlight certain areas. However, this has an influence on the visibility of the ablation when switched off. LED, Micro LED, Flecsform, OLED and LCD displays are conceivable as light sources for each of the display panels described in the above embodiments. For the predefined display, masking also makes it possible to separate the illuminated areas from each other and to achieve a sharper display. These light sources are in addition to the ultraviolet light source provided by the Q Dot light source shown and described in Figs. 4A and 4b.

The polymer substrate 502, 528, 558, 586 used in all of the embodiments above can be either a transparent material or a translucent material. Specific materials include, but are not limited to thermoplastic olefins (TPO), nylon and polycarbonate. The backlit vehicle panel 700 a-l, 524, 554, 582 , 738 used in all of the embodiments above can be either a transparent material or a translucent material depending on the light transmissibility of the layers of material.

The description of the invention is merely exemplary in nature and, thus, variations that do not depart from the gist of the invention are intended to be within the scope of the invention. Such variations are not to be regarded as a departure from the spirit and scope of the invention.

Claims

CLAIMS What is claimed is:

1 . A backlit vehicle panel comprising: a display panel of a backlit vehicle panel having light emitting surface that projects light; layers of materials that include a polymer substrate having an appearance side and a painted side, wherein the painted side receives light from the light emitting surface of the display panel; a sacrificial material layer of the layers of materials adjacent the painted side of the polymer substrate; at least one base paint layer of the layers of materials over the sacrificial material layer; an ablation zone where the at least one base paint layer and a portion of the sacrificial material layer have been removed, wherein at least a portion of the light em itting surface of the display panel aligns with the ablation zone and allows light to selectively pass through the ablation zone, and wherein when the light emitting surface of the display panel is off, the display panel is not visible through the appearance side of the layers of materials and when the light emitting surface is on, the light emitting surface is on and projecting the light, the light emitting surface is visible through the appearance side of the display panel in the ablation zone.

2. The backlit vehicle panel of claim 1 , wherein the polymer substrate is polycarbonate.

3. The backlit vehicle panel of claim 1 , wherein the sacrificial material layer is a transparent paint layer that protects the polymer substrate from damage from the ablation laser.

4. The backlit vehicle panel of claim 1 , wherein the backlit vehicle panel is part of a vehicle trim piece.

5. The backlit vehicle panel of claim 4 wherein the trim piece connected to one of the group consisting of an A-pillar, B-pillar, C-pillar, fender, side door, fascia, liftgate and hood.

6. The backlit vehicle panel of claim 1 , wherein the backlit vehicle panel is a trim piece for a charge port and displays information messages pertaining to a battery status of the vehicle are displayed on the light emitting surface.

7. The backlit vehicle panel of claim 1 , further comprising a primer layer of the layers of materials applied over the at least one base paint layer, and wherein the primer layer has been removed in the ablation zone.

8. The backlit vehicle panel of claim 7, wherein the primer layer is less than or equal to 15 microns in thickness.

9. The backlit vehicle panel of claim 7, further comprising an accent paint layer of the layers of materials applied over the primer layer and ablation zone.

10. The backlit vehicle panel of claim 9, wherein the accent paint layer is one of black or opaque.

11 . The backlit vehicle panel of claim 9, wherein the accent paint layer is a colored paint.

12. The backlit vehicle panel of claim 9, wherein the accent paint layer is between about 25 to about 30 microns in thickness.

13. The backlit vehicle panel of claim 1 , wherein a graphic design is formed in the ablation zone.

14. The backlit vehicle panel of claim 1 , further comprising a layer of hard coat material of the layers of materials applied over the appearance side of the polymer substrate.

15. The backlit vehicle panel of claim 1 , wherein the sacrificial material layer is at least 9 microns in thickness.

16. The backlit vehicle panel of claim 1 , wherein the at least one base paint layer is between about 12 to about 15 microns in thickness.

17. The backlit vehicle panel of claim 1 , wherein the at least one base paint layer is between about 22 to about 28 microns in thickness.

18. The backlit vehicle panel of claim 1 , wherein the ablation zone includes a light passage formed at an angle relative to the layers of materials.

19. The backlit vehicle panel of claim 18, wherein the angle is 45 degrees.

20. The backlit vehicle panel of claim 1 , wherein the ablation zone is a plurality of ablation zones.

21 . A backlit vehicle panel comprising: a display panel having light emitting surface that projects light and one or more sensors on the display panel that project light; layers of materials connected to the light emitting surface of the display panel and the one or more sensors, wherein the layers of materials include a polymer substrate having an appearance side and a painted side, wherein the painted side receives light from the light emitting surface of the display panel; a sacrificial material layer of the layers of materials adjacent the painted side of the polymer substrate; at least one base paint layer of the layers of materials over the sacrificial material layer; an ablation zone where the at least one base paint layer and a portion of the sacrificial material layer have been removed, wherein at least a portion of the light em itting surface of the display panel aligns with the ablation zone and allows light to selectively pass through the ablation zone; wherein when the light emitting surface of the display panel is off, the display panel is not visible through the appearance side of the layers of materials and when the light emitting surface is on, the light emitting surface is on and projecting the light, the light emitting surface is visible through the appearance side of the display panel in the ablation zone, and wherein when the one or more sensors of the display panel is off, the one or more sensors are not visible through the appearance side of the of the layers of materials and when the one or more sensors is on and projecting light, the one or more sensors are visible through the appearance side of the display panel in the ablation zone.

22. The backlit vehicle panel of claim 21 , wherein the polymer substrate is polycarbonate.

23. The backlit vehicle panel of claim 21 wherein the sacrificial material layer is a transparent paint layer that protects the polymer substrate from damage from the ablation laser.

24. The backlit vehicle panel of claim 21 , wherein the backlit vehicle panel is part of a vehicle trim piece.

25. The backlit vehicle panel of claim 24 wherein the trim piece connected to one of the group consisting of an A-pillar, B-pillar, C-pillar, fender, side door, fascia, liftgate and hood.

26. The backlit vehicle panel of claim 21 , wherein the backlit vehicle panel is a trim piece for a charge port and displays information messages pertaining to a battery status of the vehicle are displayed on the light emitting surface.

27. The backlit vehicle panel of claim 21 , further comprising a primer layer of the layers of materials applied over the at least one base paint layer, and wherein the primer layer has been removed in the ablation zone.

28. The backlit vehicle panel of claim 27, wherein the primer layer is less than or equal to 15 microns in thickness.

29. The backlit vehicle panel of claim 27, further comprising an accent paint layer of the layers of materials applied over the primer layer and ablation zone.

30. The backlit vehicle panel of claim 27, wherein the accent paint layer is one of black or opaque.

31 . The backlit vehicle panel of claim 27, wherein the accent paint layer is a colored paint.

32. The backlit vehicle panel of claim 27, wherein the accent paint layer is between about 25 to about 30 microns in thickness.

33. The backlit vehicle panel of claim 21 , wherein a graphic design is formed in the ablation zone.

34. The backlit vehicle panel of claim 21 , further comprising a layer of hard coat material of the layers of materials applied over the appearance side of the polymer substrate.

35. The backlit vehicle panel of claim 21 , wherein the sacrificial material layer is at least 9 microns in thickness.

36. The backlit vehicle panel of claim 21 , wherein the at least one base paint layer is between about 12 to about 15 microns in thickness.

37. The backlit vehicle panel of claim 21 , wherein the at least one base paint layer is between about 22 to about 28 microns in thickness.

38. The backlit vehicle panel of claim 21 , wherein the ablation zone includes a light passage formed at an angle relative to the layers of materials.

39. The backlit vehicle panel of claim 38, wherein the angle is 45 degrees.

40. The backlit vehicle panel of claim 21 , wherein the ablation zone is a plurality of ablation zones.

41 . A backlit vehicle panel comprising: a display panel of a backlit vehicle panel having a light emitting surface that projects light, wherein the display panel is a Q Dot display unit utilizing ultraviolet light waves emitted from a plurality of ultraviolet LED light sources; layers of materials that include a polymer substrate having an appearance side and a painted side, wherein the painted side receives light from the light emitting surface of the display panel; a sacrificial material layer of the layers of materials adjacent the painted side of the polymer substrate; at least one base paint layer of the layers of materials over the sacrificial material layer; an ablation zone where the at least one base paint layer and a portion of the sacrificial material layer have been removed, wherein at least a portion of the light emitting surface of the display panel aligns with the ablation zone and allows light to selectively pass through the ablation zone, and a layer carrier connected to a back side of layers of materials, wherein when the light emitting surface of the display panel is off, the display panel is not visible through the appearance side of the layers of materials and when the light emitting surface is on, the light emitting surface is on and projecting the light, the light emitting surface is visible through the appearance side of the display panel in the ablation zone.

42. The backlit vehicle panel of claim 41 further comprising: wherein the plurality of ultraviolet LED light sources are connected to a light source carrier; a layer carrier connected to connected to a back side of the layers of materials, the layer carrier holds the light source carrier with the plurality of ultraviolet LED light sources, a plurality of filters and a diffusive film, wherein light from the plurality of ultraviolet LED light sources passes through at least one of the plurality of filters, is dispersed by the diffusive film and then is transmitted through the ablation zone.

43. The backlit vehicle panel of claim 41 , wherein the polymer substrate is polycarbonate.

44. The backlit vehicle panel of claim 41 , wherein the sacrificial material layer is a transparent paint layer that protects the polymer substrate from damage from the ablation laser.

45. The backlit vehicle panel of claim 41 , wherein the backlit vehicle panel is located adjacent a charge port and displays information messages pertaining to a battery status of the vehicle are displayed on the light emitting surface.

46. The backlit vehicle panel of claim 41 , further comprising a primer layer of the layers of materials applied over the at least one base paint layer, and wherein the primer layer has been removed in the ablation zone.

47. The backlit vehicle panel of claim 46, wherein the primer layer is less than or equal to 15 microns in thickness.

48. The backlit vehicle panel of claim 46, further comprising an accent paint layer of the layers of materials applied over the primer layer and ablation zone.

49. The backlit vehicle panel of claim 48, wherein the accent paint layer is one of black or opaque.

50. The backlit vehicle panel of claim 48, wherein the accent paint layer is a colored paint.

51 . The backlit vehicle panel of claim 48, wherein the accent paint layer is between about 25 to about 30 microns in thickness.

52. The backlit vehicle panel of claim 41 , wherein a graphic design is formed in the ablation zone.

53. The backlit vehicle panel of claim 41 , further comprising a layer of hard coat material of the layers of materials applied over the appearance side of the polymer substrate.

54. The backlit vehicle panel of claim 41 , wherein the sacrificial material layer is at least 9 microns in thickness.

55. The backlit vehicle panel of claim 41 , wherein the at least one base paint layer is between about 12 to about 15 microns in thickness.

56. The backlit vehicle panel of claim 41 , wherein the at least one base paint layer is between about 22 to about 28 microns in thickness.

57. The backlit vehicle panel of claim 41 , wherein the ablation zone includes a light passage formed at an angle relative to the layers of materials surface of the panel body.

58. The backlit vehicle panel of claim 57, wherein the angle is 45 degrees.

59. The backlit vehicle panel of claim 41 , wherein the ablation zone is a plurality of ablation zones.

60. The backlit vehicle panel of claim 41 , wherein the backlit vehicle panel is part of a vehicle trim piece.

61 . The backlit vehicle panel of claim 60 wherein the trim piece connected to one of the group consisting of an A-pillar, B-pillar, C-pillar, fender, side door, fascia, liftgate and hood.

62. The backlit vehicle panel of claim 41 , wherein the backlit vehicle panel is a trim piece for a charge port and displays information messages pertaining to a battery status of the vehicle are displayed on the light emitting surface.