WO2009089092A1

WO2009089092A1 - Touch sensitive switches integrated with a vehicle interior part

Info

Publication number: WO2009089092A1
Application number: PCT/US2009/030017
Authority: WO
Inventors: Robert Hamelink; Bradley K. Meyers; Michael R. Catlin; Michael J. Sims
Original assignee: Johnson Controls Technology Company
Priority date: 2008-01-04
Filing date: 2009-01-02
Publication date: 2009-07-16

Abstract

An overhead console assembly for use at an overhead console location in a vehicle includes a housing configured for mounting to the overhead console location. The overhead console assembly further includes a switch coupled to the housing and comprising a field effect sensor and a surface finish covering the switch. The overhead console assembly further includes a light source coupled to the housing and aimed toward a vehicle interior location when the housing is mounted to the overhead console location, the switch configured to selectively activate the light source.

Description

TOUCH SENSITIVE SWITCHES INTEGRATED WITH A VEHICLE

INTERIOR PART

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of: U.S. Provisional Application No. 61/006,291, filed 1/4/2008, incorporated herein by reference in its entirety; and this application also claims the benefit of U.S. Provisional Application No. 61/060,287, filed 6/10/2008, incorporated herein by reference in its entirety.

BACKGROUND

[0002] The present disclosure generally relates to parts, systems, and/or assemblies for vehicle interiors.

[0003] Vehicle interiors typically include a number of conventional switches configured to activate vehicle devices or vehicle features. It is challenging and difficult to produce robust and easy to use switches that will withstand the abuses typically experienced in a vehicle environment.

SUMMARY

[0004] One embodiment relates to an overhead console assembly for use at an overhead console location in a vehicle. The overhead console assembly includes a housing configured for mounting to the overhead console location. The overhead console assembly further includes a switch coupled to the housing and comprising a field effect sensor and a surface finish covering the switch. The overhead console assembly further includes a light source coupled to the housing and aimed toward a vehicle interior location when the housing is mounted to the overhead console location, the switch configured to selectively activate the light source.

[0005] Another exemplary embodiment relates to an overhead console assembly for use at an overhead console location in a vehicle interior. The overhead console assembly includes a housing configured for mounting to the overhead console location and a surface finish having a front side facing the vehicle interior and a back side. The overhead console assembly further includes a switch coupled to the housing and comprising a touch sensor part. The touch sensor part is integrated with the surface finish and/or is located on the back side of the surface finish. A dielectric substrate is provided behind the surface finish and behind the touch sensor part relative to the vehicle interior. No moving parts operate to affect operation of the switch. The switch may be a capacitive switch and the touch sensor part may be a conductive layer. Conductive traces for the capacitive switch can be provided in the surface finish and/or provided behind the surface finish and between the surface finish and the rigid dielectric substrate. The switch may alternatively be a field effect switch and touch sensor part may be a field effect sensor. The switch may be configured to providing a signal indicating a user input activity to, for example, a sunroof, a remote control system for a garage door opener, a hands-free communication system, a vehicle audio system, a vehicle video system, a lighting system, a body electronics module, and/or any other system, device, or component.

[0006] Another embodiment relates to an armrest for a vehicle. The armrest includes a body configured for mounting to at least one of a vehicle seat and a floor console location. The armrest further includes a switch coupled to the body. The switch can be a capacitive sensor and/or a field effect sensor. The armrest further includes a surface finish covering the switch (e.g., a plastic, a metal, a cloth, leather, etc.).

[0007] Alternative exemplary embodiments relate to other features and combinations of features as may be generally recited in the claims.

BRIEF DESCRIPTION OF THE FIGURES

[0008] The disclosure will become more fully understood from the following detailed description, taken in conjunction with the accompanying figures, wherein like reference numerals refer to like elements, in which:

[0009] FIG. 1 is a perspective view of a vehicle including an overhead console assembly, according to an exemplary embodiment;

[0010] FIG. 2 is a more detailed perspective view of the overhead console assembly of FIG. 1, according to an exemplary embodiment;

[0011] FIGS. 3A-3B are detailed views of a field effect switch and a field effect switch assembly for the overhead console assembly of FIGS. 1-2, according to exemplary embodiments;

[0012] FIG. 4 is a detailed cross-sectional view of the overhead console assembly of FIGS. 1-2, according to an exemplary embodiment;

[0013] FIG. 5 is a block diagram of an overhead console assembly, according to an exemplary embodiment;

[0014] FIG. 6A is detailed view of an overhead console according to another exemplary embodiment; [0015] FIG. 6B is perspective view of a seat armrest having a number of integrated switches, according to another exemplary embodiment;

[0016] FIG. 7 is a representation of an overhead console assembly according to another exemplary embodiment;

[0017] FIG. 8 is a sectional view of a portion of an exemplary film layer according another exemplary embodiment;

[0018] FIG. 9 is a plan view of a portion of an exemplary film design;

[0019] FIG. 10 is sectional representation of a portion of an exemplary film layer according to an exemplary embodiment;

[0020] FIG. 11 is a plan view of a portion of an exemplary film layer according to an exemplary embodiment;

[0021] FIG. 12 is a sectional view of a portion of a second exemplary film layer according to an exemplary embodiment;

[0022] FIG. 13 contains sectional views of a portion of a third and fourth exemplary film layers according to an exemplary embodiment;

[0023] FIG. 14 is a perspective view of a portion of an exemplary film layer according to an exemplary embodiment;

[0024] FIG. 15 is a sectional view of a portion of an exemplary film layer according to an exemplary embodiment;

[0025] FIG. 16 is an exploded view of a conventional overhead console according to an exemplary embodiment;

[0026] FIG. 17 is an exploded view of an exemplary overhead console comprising an exemplary film layer according to an exemplary embodiment;

[0027] FIG. 18 is an exploded view of an exemplary overhead console comprising an exemplary film layer according to an exemplary embodiment;

[0028] FIG. 19 is an exploded view of an exemplary overhead console comprising an exemplary film layer according to an exemplary embodiment;

[0029] FIG. 20 is an exploded view of a second conventional overhead console according to an exemplary embodiment;

[0030] FIG. 21 contains perspective views of exemplary overhead console assemblies comprising an exemplary film layer according to an exemplary embodiment;

[0031] FIG. 22 contains perspective views of exemplary overhead console assemblies comprising an exemplary film layer according to an exemplary embodiment; [0032] FIG. 23 is an exploded view of an exemplary lighting assembly comprising an exemplary film layer according to an exemplary embodiment;

[0033] FIG. 24 is a perspective view of an exemplary lighting assembly comprising an exemplary film layer according to an exemplary embodiment;

[0034] FIG. 25 is a perspective view of an exemplary portion of a roof assembly comprising an exemplary film layer according to an exemplary embodiment;

[0035] FIG. 26 is a perspective view of exemplary overhead console assemblies comprising exemplary film layers according to this invention and various exemplary graphics that may be utilized in connection with various exemplary film layers according to an exemplary embodiment;

[0036] FIG. 27 contains views of portions of exemplary console assemblies comprising exemplary film layers according to this invention and various exemplary graphics that may be utilized in connection with various exemplary film layers according to an exemplary embodiment; and

[0037] FIG. 28 contains representations of various exemplary graphics and an exemplary graphical layout for an exemplary overhead console comprising an exemplary film layer according to an exemplary embodiment.

DETAILED DESCRIPTION OF THE EXEMPLARY EMBODIMENTS [0038] Before turning to the figures, which illustrate the exemplary embodiments in detail, it should be understood that the application is not limited to the details or methodology set forth in the description or illustrated in the figures. It should also be understood that the terminology is for the purpose of description only and should not be regarded as limiting.

[0039] Referring to FIG. 1, vehicle 100 is shown that may include a number of subsystems for vehicle operation, user convenience, and/or entertainment. For example, vehicle 100 may include a heating, ventilation, and air conditioning (HVAC) system, a lighting system, a connectivity system, a sound system, a media system, a navigational system, an entertainment system, a display system, a communications system, or any other vehicle control system.

[0040] Vehicle 100 is shown to include an overhead console assembly 102. As shown, overhead console assembly 102 may be located on the ceiling of the vehicle near the front window and between the drivers. According to other various exemplary embodiments, overhead console assembly 102 may be mounted in vehicle 100 at any other vehicle overhead console location (e.g., for a row of seats other than the front row, etc.). According to an exemplary embodiment, overhead console assembly 102 includes field effect sensors that can be used as switches or other controls (e.g., slider controls, etc.) configured to accept a user input and to use the user input to configure an operation of one or more vehicle systems of vehicle 100.

[0041] Referring now to FIG. 2, overhead console assembly 102 is shown in greater detail. Overhead console assembly is shown to include multiple switches 202 and multiple light sources 204. A user of the vehicle may use a switch 202 to selectively activate one or more of light sources 204 and/or to activate any other vehicle component or feature. According to one exemplary embodiment, switches 202 are field effect switches (e.g., switches that operate via one or more field effect sensors). Light sources 204 may be configured such that the light source may be aimed toward a vehicle interior location. According to an exemplary embodiment, field effect switches 202 include no moving parts and instead use only solid state hardware. Field effect switches 202 can be smaller than mechanical switches and can therefore be closely spaced within the housing of overhead console 102.

[0042] While the present application shows many different overhead console assemblies, it should be noted that field effect switches 202 may be located in other areas of the vehicle. For example, field effect switches 202 may be provided in or to a wide variety of interior surfaces and/or components in the vehicle interior such as center consoles, door panels, visors, rear view mirrors, the steering wheel, instrument panels, door panels, headliner panels, the dashboard, armrests 702 (see FIG. 6B), etc. In FIG. 2, field effect switches 211 and 213 are shown as located on mirror 210 and on visor 212, respectively. [0043] Referring now to FIG. 3 A, a cross sectional diagram of a field effect switch assembly is shown, according to an exemplary embodiment. The field effect switches shown and described herein can be implemented using the field effect sensor shown and described in U.S. Pat. No. 6,310,611, the entirety of which is hereby incorporated by reference, or otherwise. The field effect switch assembly is shown to include a surface finish 306 covering field effect sensors 310, and a dielectric substrate 308 sandwiched between field effect sensors 310 and surface finish 306.

[0044] A finger (or other object) 302 may press, touch, or hover above surface finish 306. Field effect sensors 310 may include a first conductive element (e.g., a conductive pad) 330 and one or more second conductive elements 332 (e.g., outer electrodes) near first conductive element 330 (e.g., laterally surrounding the first element, partially surrounding the first element, etc.). According to an exemplary embodiment, circuitry of the switch (e.g., including a microprocessor, a power supply or connection to a power supply, etc.) can create a difference in the electrical potential between first conductive element 330 and second conductive elements 332, creating an electric field (e.g., arc shaped fields 304) which extends through dielectric substrate 308 and surface finish 306. When a finger 302 is brought within sensor fields 304, finger 302 will cause a disruption of the electric fields that is detectable by circuitry associated with the first conductor and/or the second conductor. The circuitry can be configured to interpret the detected disruptions so that sensors 310 can be used for switching purposes. Sensors 310 may be part of a flexible circuit, a rigid circuit, or otherwise. According to one exemplary embodiment, the flexible circuit may be or include a polyester film type flexible mat. According to an exemplary embodiment, sensors 310 are configured to sense a human finger brought within one inch or less of sensors 310. [0045] Referring to FIG. 3B, a cross sectional diagram of two field effect switches 202 is shown, according to an exemplary embodiment. Field effect switches 202 are shown to include one or more field effect sensors 310. According to an exemplary embodiment, surface finish 306 and dielectric substrate 308 are formed to include a depression configured to indicate the presence of a touch zone associated with sensors 310. [0046] Surface finish 306 may be or include a print pad, according to an exemplary embodiment. The print pad can include print indicating a touch zone of overhead console assembly 102 that the user may touch in order to operate switch 202. Surface finish 306 may be configured to entirely cover sensors 310 relative to the vehicle interior, as well as an area around a perimeter of sensors 310. According to various other exemplary embodiments, surface finish 306 may only cover a portion of sensors 310 and/or exactly cover an area associated with sensors 310 relative to the vehicle interior. In addition to or as an alternative to the depressions to provide a tactile indication of switch location, surface finish 306 be formed to include one or more ridges to indicate the locations of switches/sensors, according to an exemplary embodiment. Surface finish 306 may be a film applique and surface finish 306 can be formed from a variety of materials. For example, surface finish 306 can be formed from a polycarbonate material, an acrylic material, a cloth material, a leather material, a composite material, a metal material, and/or any other material through which the electric fields of sensors 310 can pass.

[0047] According to an exemplary embodiment, a plurality of sensors 310 may be placed in line so that more than one sensors are laterally adjacent to each other (e.g., as shown in

FIG. 3A) and may be coupled to circuitry configured to use the adjacent sensors to form a slider switch 704 (see FIG. 6B). Such a slider switch 704 senses the position of a user's finger along a series of sensors. Slider switches 704 may be utilized to control a wide variety of criteria such as speaker volume, temperature, HVAC fan speed, lighting level, etc.

[0048] Referring to FIG. 4, a cross sectional diagram of overhead console assembly 102 is shown, according to an exemplary embodiment. Overhead console assembly 102 is shown to include housing 406 configured for mounting to overhead console location 402 (e.g., via a coupling to a vehicle ceiling surface). Housing 402 may couple to the vehicle in any number of ways. For example, tabs 404 are shown that may be used to fasten (e.g., via a snap connection) overhead console assembly 102 to the vehicle at location 402. According to various other exemplary embodiments, other fastening methods (e.g., bolts, screws, other locking mechanisms, adhesives, etc.) may be used.

[0049] Overhead console assembly 102 is shown to include field effect switch 202 coupled to housing 406. The coupling of field effect switch 202 to housing 406 can be via an adhesive, an integral mold process, a mold-behind process, or otherwise. Switch 202 may be the switch as described in FIGS. 3A-B, including field effect sensors 310. Overhead console assembly 102 is shown to include surface finish 306 covering switch 202. Overhead console assembly 102 is also shown to include one or more light sources 204 configured to be aimed toward a vehicle interior location when overhead console assembly 102 is mounted to overhead console location 402. Switch 202 may be configured to selectively activate light source 204 when touched, pressed, or otherwise triggered by a user.

[0050] Referring now to FIG. 5, a block diagram of overhead console assembly 102 is shown, according to an exemplary embodiment. Overhead console assembly 102 may be connected to or coupled to a vehicle control system or other vehicle system 502. For example, overhead console assembly 102 can be coupled to a remote control system (e.g., a system for transmitting control signals to a garage door opener), a connectivity system, a telematics system, a hands-free phone system, a media system, an HVAC system, a lighting system, a security system, a navigation system, and/or any other vehicle system. A vehicle system to which overhead console assembly 102 is attached can be local to the overhead console assembly (e.g., mounted to the assembly, integral to the assembly, etc.) or the vehicle system can be remote from the overhead console assembly 102 (e.g., and located in a dash location, a distributed location, or any other location). Inputs received by overhead console assembly 102 may be processed and/or provided to vehicle control system 502 for execution. Overhead console assembly 102 is shown to include a circuit 505 having a processor 504 for processing the user input and an interface 508 (e.g., a wire terminal, an optical/digital terminal, connection points, solder points, jacks, wiring harness interfaces, etc.) for communicating information about the user input to vehicle control system 502. One or more switches 202, as described earlier, may be coupled to microprocessor 506 to control a variety of vehicle functions. A first light source 204 and a second light source 510 are shown as electrically coupled to microprocessor 506 and light sources 204 and 510 can be controlled by one or more switches 202 via microprocessor 506. Light sources 204 and 510 may provide a variety of lighting to the vehicle interior including backlighting, accent lighting, convenience lighting, and/or directed task lighting. As shown, second light source 510 may be configured to be laterally adjacent to light source 204 and may be coupled to a second switch or a second sensor (e.g., a switch not associated with light source 204). [0051] A top-down view of a front surface of an exemplary overhead console assembly 102 is shown in FIG. 6A according to another exemplary embodiment. A surface finish such as a film 306 may be applied to at least a portion of substrate 308 to create an aesthetically pleasing finish for overhead console 102. Film 306 may be printed to include a variety of patterns to simulate different materials (e.g., a wood grain, white porcelain, metal, chrome, glass, etc.) and finishes (e.g., flat, satin, polished, brushed, frosted, etc.). In various exemplary embodiments, the console assembly 102 is made by first creating film 306 and/or pre-forming film 306 to a desired shape. Subsequently, film 306 is placed in a mold and substrate 308 is molded to the back surface of film 306.

[0052] Film 306 may include one or more conductive circuit paths 608 provided on the back surface that are configured to be coupled to switches 202 (e.g., and/or other electronic components such as those shown in FIG. 5). During the molding process, a portion of film 306, such as a projection 610 may be shut off or masked from the mold cavity using any suitable known or later-developed structures and/or methods. As such, projection 610 does not have a substrate molded to its back surface and remains flexible. In this exemplary embodiment, projection 610 is similar to a flexible circuit board and may be usable to electrically connect conductive circuit paths 608 to the appropriate wiring provided in the vehicle to which console assembly 102 is attached.

[0053] The conductive elements, such as conductive circuit paths 608, may be made of any suitable material such as, for example, silver, copper, gold and/or carbon based conductive inks and/or paints, deposited layers of metal, conductive film layers and/or any other suitable known or later-developed conductive material. Likewise, the conductive elements, such as conductive circuit paths 608, may be provided on the back surface of film 306 (e.g., prior to molding the substrate to the back surface of the film) using any suitable method such as, for example, silk screening, painting, metal deposition, injection molding and/or any other suitable known or later-developed method.

[0054] Although the conductive elements, such as conductive circuit paths 608, switch elements, field effect sensors, and the like can be provided to and/or printed onto the back surface of film 306 before substrate 308 is molded onto the back surface of the firm, in various other exemplary embodiments, the conductive elements may be provided on any portion of overhead console assembly 102 after substrate 308 has been molded to the back surface of film 306, or even during the molding process. Likewise, other suitable methods for providing substrate 308 may be used to form overhead console assembly 102. [0055] According to one exemplary embodiment, substrate 308 may include transparent portions (e.g., substantially transparent portions such that light may pass though) aligned with openings 604 in film 306. Openings 604 in film 306 allow a portion of substrate 308 to be revealed. A light source may be provided proximate to an opening 604 such that light may be shown through opening 604 (e.g., backlighting, convenience lighting, or directed task lighting). Portions of substrate 308 may extend outward past the film to create an integrally formed task light.

[0056] The overhead console assembly may also include a speaker 606. The speaker can be coupled to a hands-free phone system configured to communicate with a mobile phone for hands-free use of the mobile phone and/or to other vehicle systems configured to use audio output. Console 102 may include a plurality of switches 202 associated with the mobile phone (e.g., answer, hang up, volume adjustment, etc.). According to one exemplary embodiment, speaker 606 may be a traditional cone-diaphragm speaker and may sit behind a multitude of openings in film 306 and/or substrate 308. According to other exemplary embodiments, speaker 606 may be a flat panel speaker integrated with film 306 and/or substrate 308 and the first panel may include a multitude of printed openings to simulate the look of a traditional speaker.

[0057] Console assembly 102 may include field effect switches 202 for a variety of other purposes such as controlling a sunroof (e.g., controlling pivoting and/or sliding of the sunroof), controlling vehicle interior lighting, controlling volume or another property for a vehicle audio or video system, controlling power accessories (e.g., side view mirrors, windows, etc.), controlling short range vehicle radio communication systems (Bluetooth ®,

Homelink ®, etc.), controlling a navigation system, controlling an intercom system, controlling a seat, controlling a seat heating system, controlling an emergency system, controlling a dome lamp, controlling a task lamp, controlling another lighting system, controlling a back-up camera, controlling a hands-free communication system, controlling a remote control system for a garage door opener, controlling a body electronics module, and/or controlling any other vehicle component or system.

[0058] According to other exemplary embodiments, the touch zones for switches 202 may be indicated in a variety of ways. For example, the touch zone may be provided on a raised surface, the touch zone may be illuminated (e.g., backlit), the border surrounding the touch zone may be illuminated, the touch zone may have a distinct surface appearance (e.g., finish, color, pattern, etc.), and/or the touch zone may include a printed indicia. [0059] According to an alternative embodiment, the switches provided to the overhead console assembly (or to any other vehicle interior elements made using the concepts described herein) may be capacitive switches rather and/or in addition to the field effect switches previously described in this application. During operation of an exemplary capacitive switch, a signal is sent across a conductive pad and the capacitance of the pad is determined. For example, a square wave signal may be provided to the pad. During normal conditions, i.e., when the switch is not being touched, the pad has a low capacitance. As such, a circuit may be provided that quickly charges and drains, such as across a resistor, the pad in tune with the square wave signal. When a foreign object, such as a user's finger, touches or comes within close proximity to the switch, the foreign object increases the capacitance of the pad. The increased capacitance slows the rate at which the pad charges and drains and may be detected by appropriate devices and/or electrical circuits. It should be appreciated that the above-outlined exemplary capacitive switch is just one type of numerous devices that may be referred to as capacitive switches and that may be useful with various exemplary embodiments of trim pieces. Other exemplary capacitive switches have multiple pads and/or conductive paths and may not need to be touched by a foreign object to be triggered. Similarly, other capacitive switches may have flexing or otherwise displaceable surfaces, popples or other functional regions as described in International Application PCT/US08/50287, which is incorporated herein by reference in its entirety. A plunger may bring a first conductive material into close proximity with a second conductive material, creating a large capacitance between the two conductive materials that signals a reaction. Conventional designs of capacitive switches create a substantially large gap between a layer of conductive coating and the show surface of the vehicle by attaching the layer of conductive coating to an interior trim piece of a vehicle. This gap can negatively impact the operation of the capacitive switch by limiting sensitivity and reliability. [0060] According to an exemplary embodiment, vehicle trim pieces such as those disclosed herein can incorporate capacitive switches so that a conductive coating can be provided on or above the trim piece without the need to use a secondary piece. These flexing or otherwise displaceable surfaces, popples or other functional regions provide tactile feedback to the user. It should be appreciated that any such capacitive switch or other appropriate switch, such as a field effect switch, may be used with various exemplary embodiments of trim pieces.

[0061] According to an exemplary embodiment, the overhead console assembly shown in FIG. 6A includes a film layer 306 that provides a show surface (e.g., the surface facing the vehicle interior) for overhead console assembly 102 and a substrate 308 that carries and supports the film layer 306. As shown in FIG. 6A, the film layer 306 defines several button or switch regions 602. The switches associated with the button or switch regions 602 may control various aspects of the vehicle. For example, in various exemplary embodiments, two of the button or switch regions 602 are used to control interior lights of the vehicle, while a third button or switch region 602 is used to control a door of the vehicle. It should be appreciated that a button or switch region 602 may be usable to operate any desirable aspect of the vehicle or other connected electrical device.

[0062] Referring further to FIG. 6A, according to an alternative embodiment, capacitive switches are provided on the back surface of the film layer 306 of the trim piece in place of field effect switches. The conductive circuit path 608 may extend from each capacitive switch, and may be used to electrically connect each capacitive switch to the rest of the control circuitry for the switch or to or other electrical components of the vehicle. Each of the conductive circuit paths 608 continues onto the projection 610 of the film layer 306. In this exemplary embodiment, the overhead console assembly is made by first pre-forming the film layer 306 to a desired shape. The capacitive switches 202 and the conductive circuit paths 608 are then provided on the back surface of the film layer 306 or otherwise to film layer 306. Subsequently, the film layer 306 is placed in a mold and the substrate 308 is molded to the back surface of the film layer 306. According to an exemplary embodiment, conductive traces for the capacitive switches are provided in the surface finish, and/or behind the surface finish and between the surface finish and the rigid dielectric substrate. [0063] An exemplary process of making a trim piece for a vehicle can include providing a film layer having a front show surface and a back surface. The process can include providing a conductive electrical circuit onto the back surface of the film layer and providing a field effect sensor or a capacitive switch in, on, over or under the film layer of the trim piece (relative to the side of the film layer that will be facing the vehicle interior). The process further includes molding a substrate to at least a first portion of the back surface of the film layer. The substrate is not molded onto at least a second portion of the back surface of the film layer. The second portion of the back surface contains at least a portion of the conductive electrical circuit.

[0064] Capacitive switches are provided in, on or over a trim piece for a vehicle. The capacitive switches include a conductive layer provided in, on or over a film layer of the trim piece. By providing the conductive layer in, on or over the trim piece, the number of components necessary to assemble the trim piece can be reduced. Additionally, the conductive layer can be located closer to the A-surface or show surface of the vehicle, while reducing or eliminating the size of air gaps between the conductive layer and the show surface of the trim piece. This can improve the sensitivity and/or the reliability of the capacitive switch.

[0065] Referring now to FIG. 6B, an armrest 702 is shown, according to an exemplary embodiment. Armrest 702 may project directly from the side of the seat and come to rest in a deployed position over a floor console assembly. According to other exemplary embodiments, armrest 702 may project from another vehicle component such as the floor console assembly. Armrest 702 is shown to include a body having a molded end having a number of switches 202 and a slider switch 704. Switches 202 and 704 can be field effect switches including field effect sensors. The body can be configured for mounting or coupling to a vehicle seat and/or to a vehicle floor console location. According to an exemplary embodiment, switches 202 and 704 are covered by a rigid and glossy surface finish. Indicators in the surface finish (or below the surface finish) are configured to be lit or backlit by one or more light sources (e.g., when the switch is being used, etc.). Switches 202 can be configured to activate, for example, a media system, an HVAC system, a lighting system, a window system, a vehicle seat system (e.g., position, heating, etc.). [0066] Referring generally to FIGS. 7-28, a portion of an automobile interior is provided with switches (e.g., field effect switches, capacitive switches), sensors (e.g., field effect switches, capacitive switches, mechanical switches, etc.), buttons, lenses or the like integrated into a protective cover of the automobile interior. By incorporating the switches, sensors, buttons, lenses and the like into a protective cover of the automobile interior, additional parts typically necessary to perform the desired functions can be eliminated. The elimination of the additional parts results in a lower cost and reduced number of steps necessary for assembly. Additionally, the elimination of the additional parts results in a reduction in the number of apertures in the protective cover and the likelihood of component failure and/or manufacturing defects associated with the additional parts. According to various exemplary embodiments shown in FIGS. 7-28, a control assembly for a portion of an automobile interior includes a film layer having at least one functional region (e.g., for lighting), a substrate provided behind at least a portion of the film layer, at least one control element (e.g., a field effect sensor, a capacitive sensor, etc.) provided behind the film layer and usable by an occupant of the vehicle by interacting with a corresponding one of the at least one functional feature regions of the film layer. [0067] FIG. 7 illustrates one exemplary embodiment of an overhead console cover 700 usable in an overhead console assembly. As shown in FIG. 8, the overhead console cover 700 includes a film 710. As shown in FIG. 8, the film 710 is provided over a supporting substrate 750. In the exemplary embodiments shown in FIGS. 7 and 8, the film 710 includes at least one exemplary embodiment of a functional region 720. As shown in FIG. 7, the functional region(s) 720 can be a button, a button region or a button profile, or a series of buttons, button regions or button profiles. The buttons, button regions or button profiles implemented by the functional regions 720 may be used to actuate any desired function of the vehicle, such as lamp power, remote control system (e.g., Homelink®) functions, hands-free phone systems (e.g., BlueConnect®) functions, connectivity functions, telematics functions, media device functions, sunroof functions, and/or other mechanical and/or electrical functions. The film 710 may be made of any material that has the desired characteristics, such as rigidity, moldability and/or flexibility, and through which the desired functions can be performed or actuated.

[0068] FIG. 8 shows a sectional view of a portion of the overhead console cover 700, including the film 710 and one exemplary embodiment of a functional region 720. As shown in FIG. 8, in various exemplary embodiments, the functional region 720 includes a button region 722 of the film 710 and a rib or extension 762 of a tracer 760. In various exemplary embodiments, the tracer 760 may be integrated, incorporated and/or inserted into or through the film 710. In various exemplary embodiments, the tracer 760 can be formed of rubber, silicone or other synthetic and/or rubber-like materials or the like. For example, the tracer 760 can be formed of Santoprene® . In various exemplary embodiments, the plastic or molded material forming the supporting substrate 750 has one or more apertures, recesses or the like 752 provided in it. In various exemplary embodiments, each functional region 720, and any corresponding tracers 760, are substantially aligned with the apertures, recesses or the like 752.

[0069] As further shown in FIG. 8, one or more switches, latches or the like 730 are provided behind or in the supporting substrate 750 and aligned with the apertures, recesses or the like 752 and the tracers 760. In various exemplary embodiments, the tracers 760 may be incorporated or inserted into a mold of a film die. In various exemplary embodiments, at least one tracer 760 is flexibly coupled to the film 710. It should be appreciated that, although the button region 722 is shown in FIG. 8 as usable to depress a plunger 732 of the switch 730, the switch 730 can be replaced with any suitable electrical controller, such as a field effect switch and/or field effect sensor, a capacitive switch, proximity switch or the like.

[0070] As shown in FIGS. 8-11, in various exemplary embodiments, the film 710 includes at least one functional region 720 that is separated from other functional regions 720 and/or other areas of the film 710 by at least one slot 724, which allows additional functional properties or geometries, such as flex. For example, as shown in FIG. 9, a functional region 720 has a button region 722 that is coupled to the rest of the film 710 along or about a hinge line 770 and separated from the film 710 on all other sides by a slot 724. It should be appreciated that the flexibility of the button region 722 of the functional region 720 along or about the hinge line 770 can be improved by reducing the thickness of at least a portion of the supporting substrate 750 and/or a portion of the button region 722 and/or the film 710 near the hinge line 770. As shown in FIG. 9, in various exemplary embodiments, first and second ends of the slot 724 help create the pivot point or hinge line 770, such that the surface of the functional region 720 behaves like a cantilever, with a ridged or fixed end anchored on or about the hinge line 770 of the film 710.

[0071] The slot 724 may be formed by any material removal or fabrication process including stamping, etching, cutting, molding or casting. The slot 724 may be of any suitable size and configuration. In one embodiment, the slot 724 may be substantially 3 mm wide. The button region 722 of the functional region 720 may also be of any suitable size and configuration. In one embodiment, the button region 722 may be approximately 25 mm wide.

[0072] The tracer 760 may be inserted in the slot 724 such that the rib 762 extends through the slot 724. In various exemplary embodiments of the present invention, the tracer 760 is inserted into a mold cavity of the film 710. As shown in FIG. 10, in one embodiment, the tracer 760 that outlines a portion of the margin of the button region 722 of the functional region 720 is inserted into the mold cavity of the film 710 and the rib or protrusion 762 is formed and raised at an angle.

[0073] Among other things, the tracer 760 may be utilized to provide a tactile surface. As shown in FIG. 10, the tracer 760 may be raised from the surface of the film 710. For example, the tracer 760 may be substantially 0.8 mm above the surface of the film 710. The raised nature of the rib 762 of the tracer 760 in relation to the surface of the film 710 allows for tactile feedback to a user and helps define the edges of the button region 722 of the functional region 720. In another embodiment, however, at least a portion of the tracer 760 may be set below the surface of the film 710, leaving a recess. Again, the change in elevation between the tracer 760 and the surface of the film 710 provides tactile feedback to the user and helps define the edges of the button region 722 of the functional region 720. [0074] It should be appreciated that, by providing tactile feedback to define the edges of the button region 722 of the functional region 720, the tracer 760 improves the usability of the functional region 720 and allows a user to operate the functional region 720 in low-light or no-light conditions, as well as when the user is not looking directly at the functional region 720. The tracer 760 may be formed using any suitable material. In various exemplary embodiments, the tracer 760 is formed using a rubber or rubber-type material. In various exemplary embodiments, the tracer 760 is formed using a soft feel material. The tracer 760 may extend a slot and may be used to define a single functional region 720 or multiple functional regions 720.

[0075] Another structure that improves the tactile feedback and edge definition of the functional region(s) 720 is shown in FIGS. 12-15. As shown in FIGS. 12-15, the film 710, and at least one functional region 720, need not be substantially planar. As shown in FIG. 12, in various exemplary embodiments, at least one draw or deep recess 740 may be provided in the film 710 to help define at least one functional region 720. In various exemplary embodiments, a plurality of functional regions 720 may be separated by a number of the draws or deep recesses 740 to help define, at least in part, the shapes of the functional regions 720. It should be appreciated that a tracer 760, a plastic cap or the like may be provided between the functional region 720 and the switches 730. In the exemplary embodiment shown in FIG. 12, the tracer 760, the plastic cap or the like is omitted. [0076] As shown in FIG. 13, in various exemplary embodiments, the functional region 720 may include a popple 726 formed in the film 710. The popple 726 may be of any suitable size and shape. As shown in FIG. 14, in one embodiment, the popples 726 are square or rectangular in shape with a size of 20 to 25 mm square and may be raised .25 to .5 mm from the otherwise planar surface of the film 710. As shown in FIG. 15 in one embodiment of the present invention, the film 710 may comprise a plurality of popples 726. The popples 726 may be spaced relatively close together. For example, the popples 726 in one embodiment of the present invention may be spaced apart by 7 mm or less. [0077] Referring back to FIG. 13, the use of popples 726 is not limited to changing elevations and defining button regions 722. As such, the film 710 need not include the raised popples 726 shown in FIGS. 13-15. Rather, the film 710 may include one or more popples 728 that are substantially flat, smooth and/or flush with the surface of the film 710 when in their rest state, i.e., when they are not being depressed by a user. In such exemplary embodiments, other structures usable to define the edges of the functional region 720 and/or to provide tactile feedback may be used.

[0078] Other variations of the various exemplary embodiments of the present invention outlined herein may also be used. For example, the film 710 may utilize field effect sensors, capacitance switching, proximity sensors or the like. [0079] Referring to FIGS. 7-15, in various exemplary embodiments, the film 710 including the at least one functional region 720 is formed from a single sheet of material. The material may be any substance having suitable rigidity and flexibility characteristics. In various exemplary embodiments, the film 710 is a resilient material such as silicone. The film 710 may also be formed using some other elastomeric material. In various exemplary embodiments, at least a portion of the material forming the film 710 is transparent or translucent, to permit emanation or backlighting. In such exemplary embodiments, the portion of the film 710 which is transparent or translucent may be a thinned portion of the same material forming the rest of the film 710. In various exemplary embodiments, the material forming the film 710 may be substantially opaque. The film 710 including the at least one functional region 720, may also be of any suitable thickness. For example, the thickness of the film 710 may range from 0.005 - 0.030 inches. In various exemplary embodiments, the film 710 may be substantially 0.010 inches in thickness. [0080] The plastic or molded material used to form the supporting substrate 750 may also be any suitable material. In various exemplary embodiments, the plastic or molded material can include a polycarbonate material. The supporting substrate 750 may also be of any suitable size, shape or configuration.

[0081] As shown in FIGS. 16-24, by forming or providing one or more functional regions, such as button regions, lenses and/or bezels into the film, a reduction in cost and complexity of the assembly is achieved. For example, as depicted in FIGS. 16-20, various embodiments of the present invention offer a number of advantages, including less tooling, less capital, and fewer part numbers. For example, FIG. 16 illustrates an exploded view of a traditional overhead console unit. Automobile consoles, including overhead consoles, typically include a protective cover 800 with apertures through or into which at least one button, bezel and/or lens 802 may be fit and be accessible to the user. The buttons may be formed by a variety of manufacturing processes, including stamping and/or injection molding. By incorporating independent buttons, lenses, and/or bezels 802 that are separate from the protective cover 800, prior art designs require numerous parts and numerous assembly steps to combine the buttons, lenses and/or bezels 802 with the protective cover 800.

[0082] Referring now to FIGS. 17-19, a first exemplary film 810 allows various functional regions or features 820, such as lenses, bezels and buttons, to be provided as portions of the film 810. Specifically, FIG. 17 illustrates an exemplary film 810 having at least one functional region 820, comprising at least one bezel or bezel appearance 821, as part of the film 810.

[0083] Referring to FIG. 18, a second exemplary film 810 also has at least one functional region 820, comprising at least one lens or lens appearance 822, as part of the film 810. Referring to FIG. 19, a third exemplary film 810 has at least one functional region 820, comprising at least one bezel or bezel appearance 821, at least one lens or lens appearance 822, and at least one button 824, as part of the film 810. In comparison, the traditional overhead console units shown in FIGS. 16 and 20 require a greater number of parts and incur associated costs to create and assemble the additional parts. [0084] The provision of buttons and/or button regions 824, bezels and/or bezel appearances 821 and/or lenses and/or lens appearances 822 as part of the film 810, rather than as elements separate from the film 810, also generally reduces, if not prevents, liquids, debris and other unwanted matter from entering spaces between the switches and simplifies the cleaning of consoles and other assemblies incorporating such switches. [0085] In addition, as shown in FIGS . 21 -22, the use of the films 710 and/or 810 allows the use of a multitude of finishes and graphics on various consoles and automobile components. In various exemplary embodiments, a die is preheated with a desired surface finish such as a metallic finish, an animal grain finish, and any other suitable finish or finishes. In various exemplary embodiments, at least one desired surface finish may be printed onto and/or into the film 710 or 810. High gloss, low gloss, leather, chrome, textures, patterns, and any number of other finishes and graphics may be used in connection with the various embodiments of the film 710 or 810 according to the present invention. In some exemplary embodiments, some or all of the functional regions 720, such as the buttons and/or button regions 824, bezels and/or bezel appearances 820 and/or lenses and/or lens appearances 822, have graphics thereon or therein for indicating the specific functionality, and/or providing other information associated with the functional regions 720. In some such embodiments, the graphics on or in the functional regions 720, such as the buttons and/or button regions 824, the bezels and/or bezel appearances 821 and/or the lenses and/or lens appearances 822 are backlit.

[0086] FIGS. 23-28 illustrate various ways an exemplary film 710 may be incorporated into a variety of interior features and consoles, including an overhead interior lighting assembly 840, and a roof assembly 850 or a portion of a roof assembly 850. As shown in FIG. 23, an overhead lighting assembly 840 may incorporate a film 710 having a number of functional regions 720 usable to control and/or activate the lighting features of the overhead lighting assembly 840. For example, functional regions 720 designed according to any of the above-outlined embodiments and/or according to any separate embodiments, may be incorporated into a portion of the overhead lighting assembly 840 to control and/or activate at least one overhead light. As shown in FIG. 24, the overhead lighting assembly 840 may take any desired shape and may comprise any number of separate parts or layers, including being a single piece.

[0087] As shown in FIG. 25, exemplary embodiments of a film 710 having a number of the functional regions 720 may be incorporated into a roof assembly 850 or a portion of a roof assembly 850. The film 710 and functional regions 720 may be designed according to any of the above-outlined embodiments and/or any separate embodiments. By using the exemplary film 710, additional space may be made available in the roof assembly 850 for other features, such as vanity mirrors, control panels and/or display screens 860. As shown in FIG. 26, the roof assembly 850 may have backlit designs and/or indicia that identify the functional regions 720. As shown in FIG. 27, the functional regions 720 may control aspects of a display screen 860 and/or media displayed on the display screen 860. It should be appreciated that, as stated above, the functional regions 720 may be used to control any desired aspect of the automobile, including lighting controls, remote control system (e.g., Homelink®) controls, media controls, sunroof controls, power window controls and/or any other desired electrical control and/or mechanical feature of the automobile. As shown in FIG. 28, the functional regions 720 may be defined and/or identified by backlit and/or printed graphics or indicia 721. [0088] While the exemplary embodiments illustrated in the figures and described herein are presently preferred, it should be understood that the embodiments are offered by way of example only. Accordingly, the present application is not limited to a particular embodiment, but extends to various modifications that nevertheless fall within the scope of the appended claims.

[0089] The embodiments of the present disclosure may be implemented using existing computer processors, or by a special purpose computer processor for an appropriate system, incorporated for this or another purpose, or by a hardwired system. [0090] For purposes of this disclosure, the term "coupled" means the joining of two components (electrical and/or mechanical) directly or indirectly to one another. Such joining may be stationary in nature or movable in nature. Such joining may be achieved with the two components (electrical or mechanical) and any additional intermediate members being integrally formed as a single unitary body with one another or with the two components or the two components and any additional member being attached to one another. Such joining may be permanent in nature or alternatively may be removable or releasable in nature.

[0091] The construction and arrangement of the shown exemplary embodiments are illustrative only. Although only a few embodiments have been described in detail in this disclosure, many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations, etc.). For example, the position of elements may be reversed or otherwise varied and the nature or number of discrete elements or positions may be altered or varied. Accordingly, all such modifications are intended to be included within the scope of the present disclosure.

Claims

What is claimed is:

1. An overhead console assembly for use at an overhead console location in a vehicle interior, the overhead console assembly comprising: a housing configured for mounting to the overhead console location; a switch coupled to the housing and comprising a field effect sensor; and a surface finish covering the switch.

2. The overhead console assembly of Claim 1, further comprising: a light source coupled to the housing and aimed toward a vehicle interior location when the housing is mounted to the overhead console location, the switch configured to selectively activate the light source.

3. The overhead console assembly of Claim 1, further comprising: a dielectric substrate sandwiched between the switch and the surface finish.

4. The overhead console assembly of Claim 2, wherein the dielectric substrate is formed to include a depression configured to indicate the presence of a touch zone associated with the sensor.

5. The overhead console assembly of Claim 1, wherein the surface finish comprises at least one of a print pad including print indicating a touch zone and a molded ridge surrounding a perimeter of the sensor.

6. The overhead console assembly of Claim 1, wherein the switch is part of a flexible circuit.

7. The overhead console assembly of Claim 1, wherein the flexible circuit is a polyester film type flexible mat.

8. The overhead console assembly of Claim 1, wherein the switch couples to a microprocessor configured to controllably adjust at least one of range and sensitivity of the sensor.

9. The overhead console assembly of Claim 1, wherein the sensor is configured to activate the light source when the surface finish is touched by a human finger.

10. The overhead console assembly of Claim 1, wherein surface finish is at least one a film applique, a polycarbonate material, an acrylic material, a cloth material, a leather material, a composite material, and a metal material.

11. The overhead console assembly of Claim 1 , wherein the switch is a solid state electrical device and does not include any moving parts, and wherein the overhead console assembly does not include any moving parts.

12. An overhead console assembly for use at an overhead console location in a vehicle interior, the overhead console assembly comprising: a housing configured for mounting to the overhead console location; a surface finish having a front side facing the vehicle interior and a back side; a switch coupled to the housing and comprising a touch sensor part, wherein the touch sensor part is at least one of integrated with the surface finish and located on the back side of the surface finish; and a dielectric substrate provided behind the surface finish and behind the touch sensor part relative to the vehicle interior, wherein no moving parts operate to effect operation of the switch.

13. The overhead console assembly of Claim 12, wherein the switch is a capacitive switch and the touch sensor part is a conductive layer, wherein conductive traces for the capacitive switch are at least one of:

(a) provided in the surface finish, and

(b) behind the surface finish and between the surface finish and the rigid dielectric substrate.

14. The overhead console assembly of Claim 12, wherein the switch is a field effect switch and wherein the touch sensor part is a field effect sensor, wherein the switch is configured to provide a signal indicating a user input activity to at least one of:

(a) a sunroof,

(b) a remote control system for a garage door opener,

(c) a hands-free communication system,

(d) a vehicle audio system,

(e) a vehicle video system,

(f) a lighting system, and

(g) a body electronics module.

15. An armrest for a vehicle, comprising: a body configured for mounting to at least one of a vehicle seat and a floor console location; a switch coupled to the body and comprising at least one of a capacitive sensor and a field effect sensor; and a surface finish covering the switch.