WO2003049968A1

WO2003049968A1 - Automotive trim surface having integrated switches and controls

Info

Publication number: WO2003049968A1
Application number: PCT/US2002/038651
Authority: WO
Inventors: Timothy F. O'brien; Robert J. Startup; Lisa A. Kidd
Original assignee: Intier Automotive Inc.
Priority date: 2001-12-05
Filing date: 2002-12-04
Publication date: 2003-06-19
Also published as: AU2002366597A1

Abstract

A switch device is provided that comprises a switch component (10) having at least one contact (42) and a flexible trim component (12) covering the switch component (10). The flexible trim component (12) comprises an exterior surface or 'skin' (34) of a separate component into which the switch component (10) is installed. The flexible trim component (12) further includes at least one integrally formed button positioned substantially over the contact (42). At least one electrically conductive member (48) is disposed between the button (26) and the contact (42), whereby depression of at least a portion of the button (26) causes the conductive member (48) to touch the contact to complete a circuit in the switch component (10).

Description

AUTOMOTIVE TRIM SURFACE HAVING INTEGRATED SWITCHES AND

CONTROLS

BACKGROUND OF THE INVENTION

Field of the Invention

The present invention relates generally to automotive interior trim components, and more particularly to automotive interior trim surfaces having integrated switches and controls.

Description of the Related Art

Incorporating switch components, such as door lock switches or window operation switches, into an automotive interior trim component, such as a door panel, is known in the art. One technique is to attach separately manufactured switch banks and/or controls to interior trim components and sub-assemblies. Once installed these switches and controls protrude out of the corresponding interior trim component in which they are installed, enabling an occupant of the vehicle to manipulate the switch or control. A limitation of this approach is that the switch banks and controls are exposed to dirt and other debris, which tend to prematurely degrade the performance of conventional switch banks and controls. Another limitation is that conventional switch banks and controls used in automotive interior applications are relatively large limiting their use in the ever-shrinking packaging space of a modern automotive interior.

SUMMARY OF THE INVENTION

The present invention overcomes the limitations of the prior art by providing a switch component that is at least partially formed in an exterior surface or "skin" of an automotive interior trim component. Among other advantages, the present invention eliminates the use of conventional switch banks and controls. Another advantage is that the exterior surface or "skin" protects the switch component from dirt, liquids and other debris, unlike the prior art. Yet another advantage is that the present invention allows the switch component to be disassembled from the trim component if service is required. BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an exploded perspective view showing a trim component and a switch component according to a preferred embodiment of the present invention.

FIG. 2 is an exploded view showing a different perspective of the present invention.

FIG. 3 is a perspective view of an inner surface of the trim component showing the attached switch component.

FIG. 4 is a perspective view of an exterior surface of the trim component according to an embodiment of the present invention.

FIG. 5 is a cross-sectional view of the trim component according to a preferred embodiment of the present invention.

FIGS. 6A and 6B are a top view and perspective view, respectively, of the individual members of the switch component.

DESCRIPTION OF THE PREFERRED EMBODIMENT

Referring now to the drawings, preferred embodiments of the present invention are described in detail. Referring to FIG. 1, an exploded view of an embodiment of the present invention is shown illustrating a switch component 10 prior to assembly onto an automotive interior trim component 12. In the illustrated embodiment, trim component 12 functions as an exterior surface or "skin" of an automotive interior door panel (not illustrated). However, it will be appreciated that the present invention is not limited to use in a door panel, but may be incorporated into other automotive trim surfaces, such as, for example, an instrument panel, over-head system or center console. Moreover, it will also be appreciated that the present invention is not limited to use in an automobile, but may be employed in other settings where a switch or control is required.

In the illustrated embodiment, an outer surface 14 of trim component 12 is exposed to the automobile cabin and an inner surface 16 faces the inner components of the door panel. As illustrated in FIGS. 2 and 3, inner surface 16 of trim component 12 preferably includes a recess 18 that receives switch component 10 such that a bottom surface 19 of switch component 10 may be substantially flush with the inner surface 16 of trim component 12. Depending on the thickness of the trim component 12, recess 18 may create a protrusion, denoted as element 20 in FIG. 1, that extends outwardly from outer surface 14. To facilitate alignment and retention of switch component 10 into recess 18, trim component 12 preferably includes a plurality of bosses 22 that extend downward from recess 18, as illustrated in FIG. 2. Bosses 22 are configured in size, shape and position to mate with a plurality of apertures 24 in switch component 10 during assembly to precisely align switch component 10 within recess 18, as illustrated in FIG. 3.

Referring to FIGS. 1 and 4, trim component 12 includes a plurality of integrally formed buttons 26 that preferably extend away from outer surface 14. In the illustrated embodiment, buttons 26 are configured in size, shape and position to correspond to a particular function or set of functions for controlling operation of a feature of the automobile. For example, the button denoted by the element number 28 in FIG. 4 may be used to adjust the position of a side view mirror, whereas the button denoted by the element number 30 may be used to raise and lower a side window of the automobile.

Referring to FIG. 5, a cross-sectional view of trim component 12 is shown in detail. Trim component 12 preferably includes at least two layers, wherein a first layer 32 of the trim component 12 comprises a polymeric material, such as polyurethane, that is processed to define the shape of the trim component 12. The resiliency of the polymeric material provides trim component 12 with the required flexibility to enable buttons 26 to be depressed repeatedly without damage.

A second or outer layer 34 of trim component 12 functions as a decorative layer. Second layer 34 preferably comprises a layer of water-based paint, but is not intended to be so limited. Accordingly, second layer 34 may comprise other materials, such as, for example, a solvent-based paint or a polymer.

The trim component 12 is preferably manufactured using a Reaction Injection Molding (RDM) process, which involves the rapid injection of a mixture of reactive materials into a closed mold through a self-cleaning mixing head mounted directly in the mold. When the trim component 12 is formed using the RIM process, second layer 34 is preferably applied to the mold prior to injection of the polymeric material, such as, for example, by a spraying second layer 34 into the mold. Among other advantages, the RIM process enables the precise reproduction of intricate parts and patterns allowing features, such as buttons 26 and bosses 22, to be integrally formed with trim component 12.

Referring again to FIG. 4, each button 26 preferably includes one or more labels 36 that are visible on the surface of each button 26 for identifying its respective function. For example, each end of button 30 may include a directional arrow to indicate the direction of window travel. In a preferred embodiment, labels 36 are etched into second layer 34 permitting at least a small degree of light to pass through the layer. Labels 36 may be etched using a laser, for example, to burn a substantial portion of second layer 34 away to expose the first layer 32. An electroluminescent device (not illustrated), such as a light emitting diode (LED), may be placed between the switch component 10 and the trim component 12 to illuminate labels 36. Alternatively, other means may be used to identify the function of buttons 26 such as, for example, painting labels 36 directly onto the surface of buttons 26.

Referring to FIGS. 6A and 6B, a preferred embodiment of the switch component 10 is shown in detail. Referring specifically to FIG. 6A, switch component 10 comprises an intermediate member 38 that overlays a circuit board 40. Circuit board 40 includes a plurality of contacts 42 that communicate electrically with a plurality of corresponding terminals 44. In a preferred embodiment, intermediate member 38 comprises a base 46 having a plurality of dome-shaped electrically conductive elements or "domes" 48 that extend outwardly from base 46. Domes 48 provide a means of filling the gap between buttons 26 and contacts 42 and function to complete a circuit on circuit board 40 when an underside of domes 48 are forced to touch contacts 42. Base 46 preferably exhibits adhesive properties enabling intermediate member 38 to be adhered to circuit board 40 to ensure that each dome 48 is properly aligned over a corresponding contact 42.

In an another embodiment, the underside of each button 26 may include an integrally formed finger-like member (not illustrated), a distal end of which includes an electrically conductive element. In this embodiment, when at least a portion of the button 26 is depressed, the electrically conductive element is forced to touch a corresponding contact 42 on circuit board 40 to complete a circuit. It will be appreciated that the switch component 10 is not limited to the embodiments described above, but may include other devices for completing a circuit, such as a non-contacting type proximity switch.

As illustrated in FIG. 2, the switch component 10 is assembled onto the trim component 12 by aligning the apertures 24 in the intermediate member 38 and the circuit board 40 with bosses 22 and inserting the switch component 10 into recess 18. Although not illustrated, switch component 10 may be securely fixed to trim component 12 by capping the ends of bosses 22 or otherwise preventing switch component 10 from being removed from bosses 22, such as, for example, by heat staking the ends of bosses 22. When the intermediate member 38 and circuit board 40 are assembled onto trim component 12, an underside of each dome 48 on intermediate member 38 overlays, but is not in direct contact with, a corresponding contact 42 on circuit board 40. Similarly, each button 26 on trim component 12 overlays one or more corresponding domes 48 on intermediate member 38. When a button 26 or a portion of a button is depressed, the corresponding dome 48 beneath the depressed button 26 is forced against a corresponding contact 42 on circuit board 40 to complete a circuit. For example, depressing the portion of button 30 labeled with an upwardly directed arrow forces a dome 48 beneath button 30 to touch a contact 42 beneath the dome 48 to complete a circuit that allows a window to travel in a closed direction.

Among other advantages, the present invention eliminates the use of conventional switch banks and controls. Another advantage is that the trim component or "skin" protects the switch component from dirt, liquids and other debris, unlike the prior art. Yet another advantage is that the present invention allows the switch component to be easily disassembled from the trim component if service is required.

While the invention has been specifically described in connection with certain specific embodiments thereof, it is to be understood that this is by way of illustration and not of limitation, and the scope of the appended claims should be construed as broadly as the prior art will permit.

Claims

CLAIMSWhat is claimed is:

1. A switch device for an automotive interior trim surface comprising:

a switch component; and

a flexible trim component covering the switch component, the trim component including at least one integrally formed button.

2. A switch device according to claim 1, wherein the trim component comprises an outer skin of a trim surface.

3. A switch device according to claim 1, wherein each button includes a label that denotes a function or set of functions of the button.

4. A switch device according to claim 3, wherein the label is etched into the button.

5. A switch device according to claim 4 further including an electroluminescent device disposed between the switch component and the trim component to illuminate the etched label on the button.

6. A switch device according to claim 1, wherein the trim component includes an outer surface and an inner surface, the inner surface including a recess for receiving the switch component.

7. A switch device according to claim 6, wherein the recess includes a plurality of bosses that extend away from the inner surface.

8. A switch device according to claim 7, wherein the switch component includes a plurality of apertures that are configured to mate with the bosses as the switch component is received into the recess.

9. A switch device according to claim 6, wherein the buttons extend away from the outer surface of the trim component.

10. A switch device according to claim 1, wherein the switch-component includes at least one contact.

11. A switch device according to claim 10 further including at least one electrically conductive member disposed between the button and the contact, wherein depression of at least a portion of the button causes the electrically conductive member to touch the contact to complete a circuit in the switch component.

12. A switch device according to claim 11, wherein the electrically conductive member is dome-shaped to fill the gap between the button and the contact.