U.S. patent application number 15/132732 was filed with the patent office on 2017-10-19 for iridescent badges for vehicles and methods of making the same.
This patent application is currently assigned to Ford Global Technologies, LLC. The applicant listed for this patent is Ford Global Technologies, LLC. Invention is credited to Paul Kenneth Dellock, Talat Karmo, Michael Musleh, Stuart C. Salter, Chester Stanislaus Walawender.
Application Number | 20170297507 15/132732 |
Document ID | / |
Family ID | 59981048 |
Filed Date | 2017-10-19 |
United States Patent
Application |
20170297507 |
Kind Code |
A1 |
Dellock; Paul Kenneth ; et
al. |
October 19, 2017 |
IRIDESCENT BADGES FOR VEHICLES AND METHODS OF MAKING THE SAME
Abstract
An iridescent vehicle badge (and methods for making it) that
includes a translucent, polymeric badge having a non-planar shape
and comprising an interior and an exterior surface. Further, at
least one of the surfaces of the badge comprises a plurality of
diffraction gratings that are integral with the badge, each having
a thickness from 250 nm to 1000 nm and a varying period from 50 nm
to 5 microns. In some cases, the thickness can range from 500 nm to
750 nm. The period, in some cases, can vary within a set of
discrete values in one or more portions of the at least one of the
surfaces of the badge, e.g., from 150 nm to 400 nm.
Inventors: |
Dellock; Paul Kenneth;
(Northville, MI) ; Salter; Stuart C.; (White Lake,
MI) ; Karmo; Talat; (Waterford, MI) ; Musleh;
Michael; (Canton, MI) ; Walawender; Chester
Stanislaus; (Livonia, MI) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Ford Global Technologies, LLC |
Dearborn |
MI |
US |
|
|
Assignee: |
Ford Global Technologies,
LLC
Dearborn
MI
|
Family ID: |
59981048 |
Appl. No.: |
15/132732 |
Filed: |
April 19, 2016 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
G09F 21/04 20130101;
B60R 13/005 20130101; B29C 33/40 20130101; B29C 33/424 20130101;
B29C 45/263 20130101; B29L 2031/744 20130101; G09F 2007/1882
20130101; B29C 45/372 20130101; B29C 33/3842 20130101; B29D
11/00769 20130101; G09F 3/02 20130101; G09F 19/12 20130101 |
International
Class: |
B60R 13/00 20060101
B60R013/00; G09F 3/02 20060101 G09F003/02 |
Claims
1. An iridescent vehicular badge, comprising: a translucent,
polymeric badge having a non-planar shape and comprising an
interior and an exterior surface, wherein at least one of the
surfaces of the badge is non-planar and comprises a diffraction
grating integral with the badge, the grating having a thickness
from 250 nm to 1000 nm and a period from 50 nm to 5 microns.
2. The badge according to claim 1, wherein the badge has a
composition selected from the group consisting of silicones,
acrylics and polycarbonates.
3. The badge according to claim 1, wherein the grating has a
thickness from 500 nm to 750 nm and a period from 150 nm to 400
nm.
4. The badge according to claim 1, wherein the diffraction grating
comprises grooves having a triangular- or hillock-shaped
cross-section.
5. The badge according to claim 1, wherein the period of the
diffraction grating varies within the at least one of the surfaces
of the badge.
6. The badge according to claim 1, wherein the period of the
diffraction grating varies between two to five discrete values
within the at least one of the surfaces of the badge.
7. The badge according to claim 5, wherein the period of the
diffraction grating varies within a set of discrete values in one
or more portions of the at least one of the surfaces of the
badge.
8. An iridescent vehicular badge, comprising: a translucent,
polymeric badge having a non-planar shape and comprising an
interior and an exterior surface, wherein at least one of the
surfaces of the badge comprises a plurality of diffraction gratings
that are integral with the badge, each having a thickness from 250
nm to 1000 nm and a varying period from 100 nm to 5 microns.
9. The badge according to claim 8, wherein the badge has a
composition selected from the group consisting of silicones,
acrylics and polycarbonates.
10. The badge according to claim 8, wherein the at least one of the
surfaces of the badge comprising the plurality of diffraction
gratings is non-planar.
11. The badge according to claim 8, wherein each of the diffraction
gratings has a thickness from 500 nm to 750 nm and a period from
150 nm to 400 nm.
12. The badge according to claim 8, wherein each of the diffraction
gratings comprises grooves having a triangular- or hillock-shaped
cross-section.
13. The badge according to claim 8, wherein the period of each of
the diffraction gratings varies between two to five discrete values
within the at least one of the surfaces of the badge.
14. The badge according to claim 13, wherein the period of each of
the diffraction gratings varies within a set of discrete values in
one or more portions of the at least one of the surfaces of the
badge.
15. A method of making an iridescent vehicular badge, comprising:
forming a mold with mold surfaces corresponding to interior and
exterior surfaces of the badge; ablating at least one of the mold
surfaces to form a diffraction grating mold surface; and forming
the badge with a diffraction grating having a thickness from 250 nm
to 1000 nm and a period from 50 nm to 5 microns in the mold
surfaces with a polymeric material.
16. The method according to claim 15, further comprising: heating
the diffraction grating mold surface prior to the forming the badge
step.
17. The method according to claim 16, wherein the ablating step is
conducted with a laser ablation process.
18. The method according to claim 15, wherein the ablating step is
conducted to form a plurality of diffraction grating mold surfaces,
and the forming step is conducted with a polymeric material to form
the badge with a plurality of diffraction gratings, each having a
thickness from 250 nm to 1000 nm and a period from 50 nm to 10
microns.
19. The method according to claim 15, wherein at least one of the
surfaces of the badge is non-planar and comprises the diffraction
grating.
20. The method according to claim 15, wherein the polymeric
material is selected from the group consisting of silicones,
acrylics and polycarbonates.
Description
FIELD OF THE INVENTION
[0001] The present invention generally relates to iridescent
badges, trim and other exterior surfaces for vehicles and methods
of making the same, particularly automotive badges with a
jewel-like appearance.
BACKGROUND OF THE INVENTION
[0002] Car enthusiasts and owners of luxury and high-end vehicles
are continually demanding new aesthetics that justify, at least in
part, the high cost of such vehicles. Vehicle badges can be
designed to reflect the luxury and high-end nature of particular
vehicle models. For example, certain vehicle models can be more
desirable to car enthusiasts and owners with a badge having a
jewel-like appearance.
[0003] The direct incorporation of jewels and/or precious metals
into a vehicle badge can satisfy these needs in some respects.
These elements might be encapsulated within a translucent badge for
a luxurious aesthetic. Nevertheless, merely adding jewels and
precious metals to conventional badges will significantly increase
the cost of the badge, and all but the most cost-insensitive car
enthusiasts will likely object to the significant added cost of
these materials. In addition, the inclusion of jewels and/or
precious metals into a vehicular badge increases the likelihood
that it will be removed by thieves as a target of relative
opportunity.
[0004] Other approaches to upgrading the aesthetics of vehicle
badges have focused on mimicking the look of diamonds and jewels
within a molded plastic part. For example, it is feasible to make
faceted, plastic badges that attempt to approximate the look of
actual diamonds and jewels. Unfortunately, the results of such
approaches are not promising. Generally, such badges appear to look
like costume jewelry and, arguably, could detract from the overall
aesthetic of a luxury vehicle rather than enhance it.
[0005] Accordingly, there is a need for vehicular badges, trim and
other exterior surfaces (and methods of making them) that exhibit
an iridescent or jewel-like appearance without a significant cost
increase associated with the enhancement. In addition, these
iridescent, vehicular badges should maintain their appearance over
a vehicle lifetime while being exposed to a typical vehicular
environment.
SUMMARY OF THE INVENTION
[0006] According to one aspect of the present invention, an
iridescent vehicle badge is provided that includes a translucent,
polymeric badge having a non-planar shape and comprising an
interior and an exterior surface. Further, at least one of the
surfaces of the badge is non-planar and comprises a diffraction
grating integral with the badge, the grating having a thickness
from 250 nm to 1000 nm and a period from 50 nm to 5 microns.
[0007] According to another aspect of the present invention, an
iridescent vehicle badge is provided that includes a translucent,
polymeric badge having a non-planar shape and comprising an
interior and an exterior surface. Further, at least one of the
surfaces of the badge comprises a plurality of diffraction gratings
that are integral with the badge, each having a thickness from 250
nm to 1000 nm and a varying period from 50 nm to 5 microns.
[0008] According to a further aspect of the present invention, a
method of making an iridescent vehicle badge is provided that
includes the steps: forming a mold with mold surfaces corresponding
to interior and exterior surfaces of the badge; ablating at least
one of the mold surfaces to form a diffraction grating mold
surface; and forming the badge with a diffraction grating having a
thickness from 250 nm to 1000 nm and a period from 50 nm to 5
microns in the mold surfaces with a polymeric material.
[0009] These and other aspects, objects, and features of the
present invention will be understood and appreciated by those
skilled in the art upon studying the following specification,
claims, and appended drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] In the drawings:
[0011] FIG. 1 is a front perspective view of an iridescent
vehicular badge affixed to the front of a vehicle according to an
aspect of the disclosure;
[0012] FIG. 2 is a top-down, schematic plan view of an iridescent
vehicular badge according to an aspect of the disclosure;
[0013] FIG. 2A is a cross-sectional, schematic view of the badge
depicted in FIG. 2 through line IIA-IIA;
[0014] FIG. 2B is an enlarged, cross-sectional schematic view of a
diffraction grating incorporated into an interior surface of the
badge depicted in FIG. 2;
[0015] FIG. 3 is a top-down, schematic plan view of an iridescent
vehicular badge with non-planar exterior and interior surfaces
according to an aspect of the disclosure;
[0016] FIG. 3A is a cross-sectional, schematic view of the badge
depicted in FIG. 3 through line IIIA-IIIA;
[0017] FIG. 3B is an enlarged, cross-sectional schematic view of a
diffraction grating incorporated into a non-planar interior surface
of the badge depicted in FIG. 3; and
[0018] FIG. 4 is an enlarged, cross-sectional schematic view of a
diffraction grating with a varying period.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0019] For purposes of description herein, the terms "upper,"
"lower," "right," "left," "rear," "front," "vertical,"
"horizontal," "interior," "exterior," "vehicle forward," "vehicle
rearward," and derivatives thereof shall relate to the invention as
oriented in FIG. 1. However, the invention may assume various
alternative orientations, except where expressly specified to the
contrary. Also, the specific devices and assemblies illustrated in
the attached drawings and described in the following specification
are simply exemplary embodiments of the inventive concepts defined
in the appended claims. Hence, specific dimensions and other
physical characteristics relating to the embodiments disclosed
herein are not to be considered as limiting, unless the claims
expressly state otherwise.
[0020] Described in this disclosure are iridescent badges, trim and
other exterior surfaces (collectively, "iridescent vehicular
elements") for vehicles (and methods of making the same). The
iridescent vehicular elements contain one or more diffraction
gratings that are integral with the primary component(s) of the
elements (e.g., a badge member), each of which provides sparkle and
iridescence to the element. Various microscopic features can be
added or adjusted within the gratings to achieve varied aesthetic
effects. Gratings can also be incorporated into various regions
within the vehicular element to achieve other varied, aesthetic
effects. Further, these iridescent badges, trim and other
iridescent vehicular elements can be injection molded as one part,
and typically cost only marginally more than conventional badges
and trim.
[0021] Referring to FIG. 1, a front perspective view of an
iridescent vehicular badge 100, 100a affixed to the front of a
vehicle 1 is provided according to an aspect of the disclosure. As
depicted, the badge 100, 100a is characterized by an iridescent or
jewel-like appearance under ambient lighting (e.g., from the sun).
One or more diffraction gratings 20 (see FIGS. 2 and 3) configured
within an exterior and/or interior surface of the badge 100, 100a
provide the iridescent or jewel-like appearance.
[0022] As shown in FIG. 2, an iridescent vehicular badge 100 can
include a translucent, polymeric badge member 10. The badge member
10 includes one or more exterior surfaces 12 and one or more
interior surfaces 14. In some aspects, the badge member 10 is
characterized by an optical transmissivity of 85% or more over the
visible spectrum (e.g., 390 to 700 nm). Preferably, the badge
member 10 is characterized by an optical transmissivity of 90% or
more, and even more preferably, 95% or more, over the visible
spectrum. Further, the badge member 10 can be optically clear with
no substantial coloration. In other embodiments, the badge member
10 can be tinted or affixed with one or more filters on its
exterior surfaces 12 and/or interior surfaces 14 to obtain a
desired hue (e.g., blue, red, green, etc.).
[0023] Referring again to FIG. 2, badge member 10 of the iridescent
vehicular badge 100 is fabricated from a polymeric material. These
polymeric materials include thermoplastic and thermosetting
polymeric materials, e.g., silicones, acrylics and polycarbonates.
Preferably, the precursor material(s) employed to fabricate the
badge member 10 have a high flow rate and/or a low viscosity during
a molding process such as injection molding. In certain aspects,
fillers (not shown), e.g., glass beads and particles, can be added
to a polymeric material, serving as a matrix, to form the badge
member 10 without significant detriment to the optical properties
of the member. These fillers can provide added durability and/or
additional aesthetic effects to the iridescent vehicular badge 100.
Preferably, glass fillers are added in the range of 1 to 15% by
volume, depending on the nature of the filler and the desired
effect (e.g., enhanced durability, added light scattering,
etc.).
[0024] The badge member 10 of the iridescent vehicular badge 100
can take on any of a variety of shapes, depending on the nature of
the badge, vehicle insignia and other design considerations. For
example, in some embodiments, one or more of the exterior and
interior surfaces 12, 14 of the badge member 10 are planar (e.g.,
faceted), non-planar, curved or characterized by other shapes. As
also understood by those with ordinary skill in the field, the
exterior and interior surfaces 12, 14 can be characterized with
portions having planar features and portions having non-planar
features. As shown in FIGS. 2 and 2A, for example, the badge member
10 has planar (e.g., faceted) exterior and interior surfaces 12, 14
comprising diffraction gratings 20 as viewed in cross-section,
while having some curved portions in forming the overall design of
the vehicular badge 100.
[0025] Still referring to FIG. 2, the badge member 10 of the
iridescent vehicular badge 100 can consist of a single component in
a preferred embodiment. For example, the badge member 10 can be
formed as a single piece with integral diffraction grating(s) 20
from a single mold. In other aspects, the member 10 can be formed
from multiple parts, preferably with the parts joined, without
significant detriment to the overall optical properties of the
member 10.
[0026] Referring now to FIG. 2A, exterior and interior surfaces 12,
14 of the badge member 10 of the iridescent vehicular badge 100
include one or more diffraction gratings 20, preferably integral
with the badge member 10. As depicted in exemplary fashion in FIG.
2A, the iridescent vehicular badge 100 includes a badge member 10
with exterior and interior surface diffraction gratings 22, 24 on
planar portions of exterior and interior surfaces 12, 14,
respectively. Some aspects of the vehicular badge 100 include a
badge member 10 with one or more diffraction gratings 20 in the
form of exterior surface gratings 22 on one or more planar portions
of the exterior surface 12. Other aspects of the vehicular badge
100 include a badge member 10 with one or more diffraction gratings
20 in the form of interior surface gratings 24 on one or more
planar portions of the interior surface 14.
[0027] As shown schematically in FIG. 2B in cross-sectional form,
the diffraction gratings 20 of the badge member 10 of an iridescent
vehicular badge 100 are formed at a microscopic level. In an
embodiment, the diffraction gratings 20 (i.e., as inclusive of
exterior and interior surface diffraction gratings 22, 24) have a
thickness 38 that ranges from 250 nm to 1000 nm. The thickness 38
of the diffraction gratings 20, for example, should be maintained
in the range of 250 to 1000 nm to ensure that the iridescent
vehicular badge 100 (see FIGS. 2 and 2A) exhibits a jewel-like
appearance through light diffraction upon illumination in direct
ambient lighting while also having a minimal effect on the optical
clarity of the badge 100 under non-direct ambient lighting.
Preferably, the thickness 38 of the diffraction gratings 20 ranges
from about 390 nm to 700 nm. In other embodiments, the thickness 38
of the diffraction gratings 20 ranges from 500 nm to 750 nm.
[0028] As also shown schematically in FIG. 2B, the grooves of the
diffraction gratings 20 within the badge member 10 of an iridescent
vehicular badge 100 can be configured in various shapes to diffract
incident light and produce an iridescent and jewel-like appearance.
As depicted in FIG. 2B in exemplary form, the gratings 20 have a
sawtooth or triangular shape. In three dimensions, these gratings
20 can appear with a stepped or sawtooth shape without angular
features (i.e., in the direction normal to what is depicted in FIG.
2B), pyramidal in shape, or some combination of stepped and
pyramidal shapes. Other shapes of the diffraction gratings 20
include hill-shaped features (not shown)--e.g., stepped features
with one or more curved features. The diffraction gratings 20 can
also include portions with a combination of triangular and
hill-shaped features. More generally, the shapes of the gratings 20
should be such that an effective blazing angle .theta..sub.B of at
least 15 degrees is present for one or more portions of each
grating, tooth or groove of the diffraction gratings 20. The blaze
angle .theta..sub.B is the angle between step normal (i.e., the
direction normal to each step or tooth of the grating 20) and the
direction normal 40 to the exterior and interior surfaces 12, 14
having the grating 20.
[0029] Generally, the blaze angle .theta..sub.B is optimized to
maximize the efficiency of the wavelength(s) of the incident light,
typically ambient sunlight, to ensure that maximum optical power is
concentrated in one or more diffraction orders while minimizing
residual power in other orders (e.g., the zeroth order indicative
of the ambient light itself). An advantage of situating exterior
and interior surface diffraction gratings 22, 24 (see FIG. 2A) on
planar portions or aspects of the exterior and interior surfaces
12, 14 (e.g., as shown in exemplary form in FIG. 2A for a
diffraction grating 24 on a planar portion of an interior surface
14) is that a constant blaze angle .theta..sub.B and period 36 will
result in consistent reflected and diffracted light produced from
the diffraction grating. Such consistency can be employed by a
designer of the iridescent vehicular badge 100 (see FIG. 2) to
ensure that particular jewel-like effects are observable by
individuals at different locations and distances from the badge
100.
[0030] As also shown schematically in FIG. 2B, the diffraction
gratings 20 of the badge member 10 of an iridescent vehicular badge
100 are characterized by one or more periods 36 (also known as din
the standard nomenclature of diffraction gratings). In most aspects
of the vehicular badge 100 (see FIG. 2), the period 36 of the
diffraction grating 20 is maintained between about 50 nm and about
5 microns. In general, the maximum wavelength that a given
diffraction grating 20 can diffract is equal to twice the period
36. Hence, a diffraction grating 20 with a period 36 that is
maintained between about 50 nm and about 5 microns can diffract
light in an optical range of 100 nm to about 10 microns. In a
preferred embodiment, the period 36 of a diffraction grating 20 is
maintained from about 150 nm to about 400 nm, ensuring that the
grating 20 can efficiently diffract light in an optical range of
about 300 nm to about 800 nm, roughly covering the visible
spectrum.
[0031] Referring again to FIG. 2B, an interior surface diffraction
grating 24 along a portion of an interior surface 14 of a badge
member 10 is depicted in exemplary form. Incident light 50
(typically ambient, sun light) at an incident angle .alpha. is
directed against a sawtooth-shaped diffraction grating 24 having a
thickness 38, a period 36 and a blaze angle .theta..sub.B. More
particularly, a portion of the incident light 50 (preferably, a
small portion) striking the grating 24 at an incident angle .alpha.
is reflected as reflected light 50.sub.r at the same angle .alpha.,
and the remaining portion of the incident light 50 is diffracted at
particular wavelengths corresponding to diffracted light 60.sub.n,
60.sub.n+1, etc. at corresponding diffraction angles .beta..sub.n,
.beta..sub.n+1, etc. The reflected light 50.sub.r is indicative of
the zeroth order (i.e., n=0) and the diffracted light 60.sub.n,
60.sub.n+1, 60.sub.n+2 are indicative of the nth order diffraction
according to standard diffraction grating terminology, where n is
an integer corresponding to particular wavelengths of the reflected
or diffracted light.
[0032] Interior surface gratings 24, such as depicted in an
enlarged, schematic format in FIG. 2B, are advantageous within the
iridescent vehicular badge 100 (see FIGS. 2 and 2A) due to their
protected location. In particular, these gratings 24 are generally
protected from damage, alteration and/or wear due to their location
on the backside of the badge member 10. Given that incident light
50 must pass through the member 10 to reach the grating 24 and that
diffracted light 60.sub.n, 60.sub.n+1, etc., must also pass through
the member 10 to produce an iridescent effect, the diffraction
efficiency of gratings 24 can be somewhat lower than the
diffraction efficiency of the exterior surface gratings 22 (see
FIG. 2A) due to light absorption within the member 10. On the other
hand, exterior surface gratings 22, as configured within the
exterior surface 12 of the member 10 are more susceptible to
damage, alteration and/or wear than interior surface gratings 24.
Accordingly, a preferred embodiment of the vehicular badge 100
includes both exterior and interior surface diffraction gratings
22, 24 to balance diffraction efficiency and wear resistance.
[0033] Referring to FIGS. 3-3B, an iridescent vehicular badge 100a
comprising a translucent, polymeric badge member 10a with
non-planar exterior and interior surfaces 12a, 14a is depicted
according to an aspect of the disclosure. The iridescent vehicular
badge 100a shown in FIGS. 3 and 3A is similar to the iridescent
vehicular badge 100 depicted in FIGS. 2 and 2A, and like-numbered
elements have the same structure and function. The primary
difference between badges 100a and badges 100 is that the former
have a badge member 10a with non-planar portions of interior and
exterior surfaces 12a, 14a (or such surfaces 12a, 14a that are
substantially non-planar across their entire surface area) and
diffraction gratings 20a on such non-planar features. In contrast,
vehicular badges 100 have a badge member 10 with diffraction
gratings 20 located on planar portions of exterior and interior
surfaces 12, 14. By situating the diffraction gratings 20a on
non-planar portions of the interior and exterior surfaces 12a, 14a,
certain jewel-like and iridescent effects can be obtained with
badges 100a that differ from those obtained with badges 100. In all
other respects, however, the iridescent vehicular badges 100 and
100a have the same structures and functions.
[0034] Referring to FIG. 3A, the iridescent vehicular badge 100a
includes a badge member 10a with one or more diffraction gratings
20a. Further, diffraction gratings 20a include exterior and
interior surface diffraction gratings 22a and 24a, respectively,
located within or otherwise on non-planar portions of exterior and
interior surfaces 12a, 14a of the member 10a. Some aspects of the
vehicular badge 100a include a badge member 10a with one or more
diffraction gratings 20a in the form of exterior surface gratings
22a on one or more non-planar portions of the exterior surface 12a.
Other aspects of the vehicular badge 100a include a badge member
10a with one or more diffraction gratings 20a in the form of
interior surface gratings 24a on one or more non-planar portions of
the interior surface 14a.
[0035] Referring now to FIG. 3B, the cross-sectional view of the
diffraction gratings 20a within the badge member 10a of an
iridescent vehicular badge 100a are similar to the diffraction
gratings 20 in FIG. 2B. Incident light 50 (typically ambient, sun
light) at an incident angle .alpha. (see FIG. 2B) is directed
against a sawtooth-shaped diffraction grating 24a having a
thickness 38, a period 36 and a blaze angle .theta..sub.B (see FIG.
2B). More particularly, a portion of the incident light 50
(preferably, a small portion) striking the grating 24a at an
incident angle .alpha. is reflected as reflected light 50.sub.r at
the same angle .alpha. (see FIG. 2B), and the remaining portion of
the incident light 50 is diffracted at particular wavelengths
corresponding to diffracted light 60.sub.n, 60.sub.n+1, etc., at
corresponding diffraction angles .beta..sub.n and .beta..sub.n+1
(see FIG. 2B) and so on. The reflected light 50.sub.r is indicative
of the zeroth order (i.e., n=0) and the diffracted light 60.sub.n,
60.sub.n+1, etc., are indicative of the nth order diffraction
according to standard diffraction grating terminology, where n is
an integer corresponding to particular wavelengths of the reflected
or diffracted light. Given that the interior surface 14a is
non-planar in the badge 10a depicted in FIG. 3B, however, the
incident light 50 strikes each tooth at a slightly different angle,
even when the blaze angle .theta..sub.B (not shown in FIG. 3B) and
period 36 is held constant. The result is that each tooth of the
diffraction grating 20a can produce diffracted light at unique or
differing diffraction orders. For example, as shown in FIG. 3B, one
tooth of the diffraction grating can produce diffracted light
60.sub.n and 60.sub.n+1 and a different tooth can produce
diffracted light 60.sub.n+2 and 60.sub.n+3, all from the same
incident light 50. Consequently, the interior surface diffraction
grating 24a, and more generally diffraction gratings 20a,
advantageously can produce jewel-like effects of widely varying
wavelengths within small regions of the badge 100a (see FIGS. 3 and
3A).
[0036] Referring now to FIG. 4, a diffraction grating 120 with
varying periods (e.g., as including a set of periods), that can be
employed in iridescent vehicular badges 100, 100a (or other badges
consistent with the principles of the disclosure) is depicted in a
cross-sectional form according to an aspect of the disclosure. The
diffraction grating 120 is similar in most respects to the
diffraction gratings 20, 20a depicted in FIGS. 2-2B and 3-3B, with
like-numbered elements having the same structure and function.
Diffraction grating 120 differs from diffraction gratings 20, 20a
in that it contains varying periods within the same grating. In
particular, diffraction grating 120 can have two or more sets of
teeth or grooves, each having a particular period (e.g., period
136a) that can produce light at unique or differing diffraction
orders. As shown in exemplary form in FIG. 4, the grating 120 is
configured with three periods--period 136a, period 136b and period
136c. One set of teeth of the diffraction grating 120 with a period
of 136a can produce diffracted light 60.sub.n and 60.sub.n+1, a
different set of teeth with a period of 136b can produce diffracted
light 60.sub.n+2 and 60.sub.n+3, and a third set of teeth with a
period of 136c can produce diffracted light 60.sub.n+4 and
60.sub.n+5, all from the same incident light 50. Consequently, a
diffraction grating 120, whether employed on interior and/or
exterior surfaces 12, 12a, 14, 14a (see FIGS. 2A and 3A) of the
member 10, 10a, (see FIGS. 2A and 3A) advantageously can produce
jewel-like effects of widely varying wavelengths within various
regions of the badge 100, 100a (see FIGS. 2A and 3A) containing
such a grating.
[0037] In some aspects, the diffraction grating 120 includes a
varying period that varies between two to ten discrete values or,
more preferably, between two to five discrete values. According to
another aspect, a diffraction grating 120 with varying periods can
be employed in one or more portions of an exterior and/or interior
surface 12, 12a, 14, 14a of a badge member 10, 10a, and one or more
diffraction gratings 20, 20a having a constant period are employed
in other portions of the exterior and/or interior surface of the
badge member 10, 10a to create interesting, jewel-like appearance
effects produced by the vehicular badge 100, 100a employing the
gratings. In another embodiment, the diffraction grating 120
includes a varying period that changes between any number of
values, only limited by the overall length of the grating 120
and/or the processing capabilities to develop such variability
through precise control of mold dimensions.
[0038] Turning back toward iridescent vehicular badges 100, 100a
more generally, optional coatings (not shown) may be applied over
the exterior surfaces 12, 12a of the badge member 10, 10a. For
example, an optically clear sealing layer (e.g., a polyurethane
seal) can be applied over such exterior surfaces to add further
mechanical and/or ultraviolet light protection to the badges 100,
100a, particularly to any diffraction gratings 20, 20a included in
the exterior surfaces of these badges. Advantageously, the
additional of a relatively thin protective coating can protect the
diffraction gratings while retaining the benefits of locating the
grating on the exterior surface of the badge in terms of
diffraction efficiency and the overall iridescence obtained by the
badges 100, 100a.
[0039] In another aspect of the iridescent vehicular badges 100,
100a, an optional backing plate or backing layer can be applied to
the interior surfaces 14, 14a of the badge members 10, 10a of these
badges. Such a backing plate or layer can be specular (e.g.,
mirror-like) or non-specular (e.g., light-scattering), depending on
the aesthetic effect desired of the badge 100, 100a. Similarly, the
backing plate or layer can be white, grey, black or any conceivable
color. For example, a badge designer could employ a red backing
plate to produce a red-hued iridescence with a badge 100, 100a
configured on the hood of a blue-colored vehicle possessing such a
badge.
[0040] According to another aspect of the disclosure, a method of
making an iridescent vehicle badge (e.g., iridescent vehicular
badges 100, 100a) is provided that includes a step of forming a
mold with mold surfaces corresponding to interior and exterior
surfaces of the badge (e.g., exterior and interior surfaces 12,
12a, 14, 14a). Preferably, a mold is formed for this step from
metals or metal alloys sufficient to withstand the temperatures and
environmental conditions associated with injection molding a badge
member (e.g., members 10, 10a) suitable for the iridescent
vehicular badge. In a preferred embodiment, the forming a mold step
is conducted such that the mold is capable of injection molding a
single piece badge member 10, 10a.
[0041] The method of making an iridescent vehicular badge also
includes a step of ablating at least one of the mold surfaces to
form one or more diffraction grating mold surfaces. For example,
the ablating step is conducted to form one or more such diffraction
grating surfaces intended to correspond to diffraction gratings
(e.g., gratings 20, 20a and 120) intended to be incorporated in
portions of the exterior and/or interior surfaces of the badge
(e.g., badges 100, 100a). In a preferred embodiment, the ablating
step is conducted with a laser ablation process. Laser ablation
processes, e.g., employing an AgieCharmilles Laser P cutting
apparatus from Georg Fischer Ltd., are particularly adept at
developing the diffraction grating mold surfaces in the mold given
their ability to precisely ablate microscopic features into metal
and metal alloy mold surfaces.
[0042] Referring again to the method of making the iridescent
vehicular badge, it also includes a step of forming the badge
(e.g., badges 100, 100a) with a diffraction grating (e.g.,
diffraction gratings 20, 20a, 120) having a thickness from 250 nm
to 1000 nm and a period from 50 nm to 5 microns in the mold
surfaces with a polymeric material (e.g., optically clear silicone
with a high flow rate). Preferably, the forming the badge step is
conducted with an injection molding process. In a preferred aspect,
portions of the mold in proximity to the one or more diffraction
grating mold surfaces are heated prior to the step of forming the
badge. Adding additional heat to these portions of the mold serves
to further reduce the viscosity of the polymeric material such that
it can flow within the very small scale aspects of the diffraction
grating mold surfaces.
[0043] According to other aspects of the disclosure, the concepts
of the foregoing iridescent vehicular badges 100, 100a can be
applied to other iridescent vehicular elements. These elements
include exterior and interior vehicle trim, license plate holders,
hubcaps, key bezels and any other feature that might benefit from
iridescent appearance effects under ambient lighting, for example.
It is also feasible to employ molds for the creation of such
iridescent vehicular elements that can produce one-of-a-kind or
near one-of-a-kind jewel-like appearance effects. For example, an
iridescent vehicular badge 100, 100a can be designed for a mold
with a fully-symmetric badge member having one or more
symmetrically positioned diffraction grating(s) that diffract light
differently in each direction. Once a given badge has been created,
the random orientation associated with a manual or robot-driven
installation on a vehicle can create a one-of-a-kind or near
one-of-a-kind jewel-like appearance.
[0044] In a further aspect, iridescent vehicular badges 100, 100a
can be configured with diffraction gratings 20, 20a such that they
produce an iridescent appearance under day-time, ambient
illumination while balancing the reduction of sparkle and glare for
oncoming drivers under day-time or night-time conditions. Notably,
diffraction gratings 20, 20a can be placed within certain locations
of the exterior and/or interior surfaces 12, 12a, 14, 14a to
produce the desired jewel-like appearance, but only when observers
are located in positions not typical of oncoming vehicles.
[0045] Variations and modifications can be made to the
aforementioned structure without departing from the concepts of the
present invention. Such variations and modifications, and other
embodiments understood by those with skill in the field within the
scope of the disclosure, are intended to be covered by the
following claims unless these claims by their language expressly
state otherwise.
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