Integrated 3D structures for creating UIs, related devices, methods of manufacture and uses thereof

Abstract

A monolithic functional multi-layer structure (100, 200, 1100, 1200) for building a gestural UI (user interface) comprises a first surface (202a) for facing towards the environment of the multi-layer structure and a user therein, and an opposing second surface (202b) facing towards the interior of the multi-layer structure, the first surface (202a) and the second surface (202b) and the remaining material of the substrate film (202) therebetween extending from a plane (2020) of the surrounding substrate film material and locally defining three-dimensional projections (101) formed from the locally stretched and shaped material of the substrate film, the projections (101) being configured to define a plurality of substantially vertical or inclined, and optionally at least locally curved, touch-responsive projections (101). The present invention comprises a flexible 3D formable substrate film (202), preferably defining a continuous multi-sided knob (100, 200) or recess (1100, 1200) shape in a multi-layer structure having side walls (104) sensible by the projections, a circuit (206) provided on the substrate film and comprising a number of conductive traces, electrodes and / or components configured to detect contact on two or more of the side walls, preferably on the tops (201) of the projections, and at least one filler layer (208) of preferably thermoplastic filler material, disposed on the substrate film and optionally (injection) molded or cast, to at least partially fill a volume defined by the circuit and optionally the projection shapes and planes. A related manufacturing method is presented.

Description

[Technical field]

[0001] The present invention relates generally to functionally integrated structures incorporating various functional features such as electronic, mechanical, optical elements, or different combinations thereof. Specifically, but not exclusively, the present invention relates to providing UI (user interface) solutions for electronic devices via such integrated structures. [Background technology]

[0002] For example, in the field of electronics and electronic products, there are a variety of different stacked assemblies and multi-layer structures in the context of different functional ensembles. For example, the motivation behind integrating functions with electronic, mechanical, and optical features can be as diverse as the relevant use situations. Relatively often, size savings, weight savings, cost savings, or even efficient integration of parts are pursued for cases where the resulting solution ultimately exhibits multi-layered nature. The relevant use scenarios may then relate to product packaging or casing, visual design of device housings, wearable electronics, personal electronic devices, displays, detectors or sensors, vehicle interiors, antennas, labels, and vehicle electronics, etc.

[0003] Electronics such as electronic components, ICs (integrated circuits) and conductors can generally be provided on the substrate elements by several different techniques. For example, prefabricated electronics such as various surface mounted devices (SMDs) can be mounted on the substrate surface that will ultimately form the inner or outer interface of the multi-layer structure. Additionally, techniques that fall under the term "printed electronics" can be applied to actually generate electronics directly and additively on the substrate concerned. The term "printed" in this context refers to various printing techniques that can generate electronics / electrical elements from a print, including but not limited to screen printing, flexography and inkjet printing, through a substantially additive printing process. The substrates used can be flexible, but are not necessarily organic prints.

[0004] Furthermore, the concept of injection molded structural electronics (IMSE) involves building functional devices and their parts in the form of multi-layer structures, which encapsulate the electronic functionality as seamlessly as possible. A characteristic of IMSE is also that the electronics are generally manufactured in true 3D (non-planar) form according to a 3D model of the intended product, part, or generally the entire design. To achieve the desired 3D layout of the electronics on the 3D substrate and in the associated final product, the electronics may still be provided on an initial planar substrate, such as a film, using two-dimensional (2D) methods of electronics assembly, and then the substrate already housing the electronics may be formed and overmolded into the desired three-dimensional, i.e. 3D, shape, for example, by a suitable plastic material that may cover and embed the underlying elements, such as the electronics, thus protecting and potentially hiding the elements from the environment. Further layers and elements may be naturally added to the construction.

[0005] Many electronic devices require, or at least benefit from, a user interface that allows the user to control the device and obtain feedback from or through the device. Since the integration level and general complexity of electronic devices generally increases while the size may simultaneously decrease, it is not always easy to design a relevant and feasible UI without significant drawbacks. Even more advanced UIs such as rotatable controllers, touch screens, and touch pads can easily prove to be unfortunately limited in functionality, counter-intuitive, fragile, or at least ergonomically difficult, thereby causing fatigue if not serious health problems for the user, and sometimes even considered to cause danger depending on the usage situation, for example, the UI requires significant visual attention to be used while the user should focus their gaze on something other than the UI, and these situations can easily occur, for example, in traffic. Indeed, it is very common in various UIs to provide ergonomically awkward flat and touch-sensitive surfaces that users typically need to look at or see while operating, for example, the hosting smartphone, tablet, multimedia device, or various in-vehicle electronics and related functions. Providing input can easily become a risky and cumbersome task. Another quite possible UI is a rotor handle or knob, e.g., an electromechanical knob / button that allows the user to interact by physically rotating the knob in a forward / backward or left / right direction, or by pressing (moving) the knob, pressing a tap from the top. All of these solutions, in addition to having very limited practical control logic, can be prone to failure while still requiring a high degree of attention from the user to avoid erroneous inputs. Summary of the Invention

[0006] It is an object of the present invention to at least alleviate one or more of the drawbacks associated with known solutions in the context of UIs and associated electronics or at least electrically controllable devices.

[0007] This objective is achieved by various embodiments of an integrated functional multi-layer structure and related methods for using or providing the multi-layer structure.

[0008] According to one embodiment, a monolithic functional multi-layer structure for constructing a gesture UI (user interface) comprises: a flexible 3D formable substrate film comprising a first surface for facing towards the environment of the structure and a user therein, and an opposing second surface facing towards the interior of the structure, the first and second surfaces and the remaining material of the substrate film therebetween extending from the plane of the surrounding substrate film material and locally and jointly defining a three-dimensional protrusion formed from the locally stretched and shaped material of the substrate film, the protrusion defining in the multi-layer structure a plurality of substantially vertical or inclined (with respect to the plane), optionally at least locally curved, continuous multi-sided knobs, recesses or other shapes having sidewalls perceptible by touch; a circuit such as a control circuit and / or a detection circuit provided on the substrate film (e.g. directly on the substrate film or in particular on a surface of the substrate film and / or (on) any underlying layer(s) such as a further (substrate) film) and optionally at least partially contained by a volume defined by the protrusion shape and plane, said circuit comprising a number of conductive traces, electrodes and / or components configured to detect contact on two or more of the plurality of side walls, preferably on the top (i.e. knob top or recess bottom) shape of the protrusion; and at least one filler layer, preferably a thermoplastic filler material, disposed on the substrate film and optionally molded, such as by injection molding or casting, to at least partially embed the circuitry and, optionally, to at least partially fill the volume.

[0009] In various embodiments, at least a portion of the circuitry is attached or generated on, or specifically on, the second surface of the substrate film. For example, sensing elements such as one or more electrodes, attached conductors (traces), or associated drive or control circuitry can be such elements.

[0010] The host device may include an embodiment of the multi-layer structure described or characterized herein. The host device may be or may include at least one of a console, a vehicle console, a door, a roof panel, a multimedia device, a computing device, a household appliance (e.g., a cooking device, a cleaning device, a cooling device such as a refrigerator or freezer, a washer, a dryer, a heater, a lawn mower, or a lighting device), a vehicle, a road vehicle (e.g., a car or truck), a watercraft (e.g., a boat or ship), an airplane or aircraft in general, a personal communication device, or a control device. The multi-layer structure may be configured to form at least a portion of a UI, such as a control console or panel, of the host device.

[0011] The host device may be or include, for example, an armrest in some embodiments. The device may optionally be provided with an object sensor, such as an arm or wrist sensor, optionally at least one capacitive, resistive, optical and / or pressure sensor. The device may be configured to change the operational state of the structure based on data provided by the sensor, which may refer to, for example, adapting or activating touch sensing in response to detecting the presence of a user's arm or wrist on the armrest.

[0012] In accordance with one or more aspects, a structure or device according to any embodiment described or characterized herein may be used to obtain user input and, optionally, initiate a control action based on the user input.

[0013] In a further aspect, a method for making an integral multi-layer structure includes the steps of: obtaining a substrate film comprising a formable, optionally thermoformable, material, and further comprising a first surface for facing towards the environment of the structure and a user therein, and an opposite second surface for facing towards the interior of the structure; providing circuitry on the substrate film, preferably using printed electronics techniques and / or selected attachment techniques; forming the substrate film three-dimensionally such that the first and second surfaces of the formed substrate film and the remaining material therebetween locally define three-dimensional protrusions extending from a plane of the surrounding substrate film material, the protrusions defining a multi-sided knob, recess, or other shape in a structure having a plurality of substantially vertical or inclined, and optionally at least locally curved, sidewalls perceptible by touch; forming said circuitry three-dimensionally, optionally at least partially contained by a volume defined by the protrusion shape and plane, and comprising several conductive traces, electrodes and / or components configured on the substrate film to detect contact on two or more of the side walls, preferably on the top of the protrusion (i.e., the top of a knob shape or the bottom of a recess shape); and disposing, optionally by injection molding or casting, at least one filler layer, preferably of a thermoplastic filler material, on the substrate film to at least partially embed the circuitry and optionally to at least partially fill said volume.

[0014] The present invention naturally offers different advantages over a wide variety of known UIs depending on each specific embodiment. Thus, easy-to-adopt, easy-to-use, reliable and ergonomically convenient three-dimensional smart surfaces for UI purposes including providing user input can be expertly established by 3D molding, optionally thermoforming, of a suitable substrate film. Thus, the film can be transformed into a hermetically sealed and monolithic gesture sensing including touch-sensitive 3D surface (if desired), and further complemented with various electronics and further features and material layers to present a preferred UI solution for the relevant use case.

[0015] The shape established may vary between embodiments, but in various preferred ones, a multi-surface or specifically multi-faceted, such as, for example, a smart surface including four side facets with a squircle-shaped top, can actually be locally raised or lowered by 3D molding to create a knob or recess shape that a user can touch with their finger (the knob / recess) and pinch (the knob) for control input purposes, and optionally also be used for, for example, haptic or visual feedback, or to receive output from the multi-layer structure itself in general, or from a hosting or connected device.

[0016] By carefully designing the corners between the sidewalls or facets of the knob or recess, full, even 360 degree, effortless finger movement or sliding can be made possible. The vertical or angled surfaces of the sidewalls are in fact preferably rounded at the corners to allow smooth transitions between them via the user's finger(s), for both ergonomic and intuitive use. A desired number of intuitive gesture zones or segments can be configured on top of the facets and / or protrusions by the utilized sensing circuitry and associated, optionally software configurable, e.g., remotely configurable (e.g., user configurable) detection, or generally, operational logic, to implement support for detection of all desired gestures, e.g., simple finger gestures that are easy to input, while allowing a vast number of more versatile control logic options within GUI (Graphical User Interface) applications. Thus, even somewhat complex user interface controls can be created by various embodiments of the present invention with rather simple, easy to implement and execute gesture patterns within the physical user interface via raised "knob" or lowered "recess" shapes established within the overall multi-layer structure.

[0017] The multi-sided or multi-faceted 3D surfaces suggested herein are highly versatile while still providing hassle-free control logic based, for example, on single or multiple finger slide and tap inputs. In some embodiments, the detected input gestures may additionally or alternatively include non-contact gesture inputs, which may include, for example, "drawing" or pointing in the air with one or more fingers within detection range of the sensing element(s) of the multi-layer structure.

[0018] In various embodiments, detected gestures may include, for example, parallel synchronous (e.g., two fingers sliding laterally in the same direction on opposing side walls / facets of a protrusion) and parallel opposite directions in general. Furthermore, a single finger in any segment, or specifically, for example, a thumb on one segment such as a side wall / facet, and simultaneously, other finger(s) such as an adjacent or opposing index or middle finger, may be detected, and any or all of the detected fingers may be stationary or sliding, and a movement such as a lateral swipe in a particular direction on a particular side wall / facet may be associated with a control action that is different from other similar swipes in the opposite direction or from, for example, a tap action. Also, successive slides that sequentially include several adjacent side walls or surfaces of a protrusion in general may be detected.

[0019] Any of these distinguishable input gestures, including, for example, various combinations of slide and tap logic, can be associated by control logic stored in the circuit or in a connected hosting / external device with a distinctive control action, such as, for example, feature selection, activation, deactivation, or scroll action on a GUI, potentially including the control display of the control device or the device connected thereto. The association may be context-dependent or generally dynamic, as described later in this specification. Of course, gesture patterning enabled by various embodiments of the present invention further facilitates, for example, easy and intuitive pinch zooming (e.g., apart, inward, i.e., zoom in / out direction control method, which may be configured based on the embodiment), by detecting at least two moving fingers, such as thumb and index finger, on adjacent side walls / facets. In any case, the 3D shaped protruding knob or recess allows the user to naturally interact with various gesture combinations. For example, a simple scrolling action may be activated by interfacing a single side wall / facet (e.g., menu (item) movement), e.g., by sliding a finger in either lateral direction. The opposing parallel side wall / facet may then be, e.g., simple scroll+tap UI logic or (thumb) tap logic making "mouse logic". Performing similar scrolling logic with two opposing parallel facets, but when the gesture is made in the opposite direction, may trigger, e.g., a faster movement option in a menu, or activate a selection, e.g., a per-segment GUI / UI interaction control.

[0020] The multi-layered structure, and in particular the knobs or recess-establishing protrusions provided therein, may also integrate and / or adjoin several visual aids, such as static images, including, for example, informative graphics such as instruction symbols. Alternatively or additionally, the visual aids may include dynamic images, such as dynamically controllable lighting, optionally several LEDs, to provide the user with guidance (e.g., a display of an active touch surface, such as a sidewall / facet or top of the structure), feedback (e.g., a display of a gesture detected with an associated visual response, such as a characterization of an activated light(s) or lighting sequence), or other output, such as device or specific feature status information.

[0021] In addition to providing integrated UI features for a particular host device, for example by integrating an embodiment of the proposed multi-layer structure within the housing of the device, various embodiments of the present invention may be utilized to provide a more general control device, for example to replace a mouse. The control device may be additionally configured to detect its own rotation along a selected axis, such as its vertical axis, and further configured to perform an associated control action. This control device may be wired or wirelessly connected to any of several target devices to be controlled, as desired. Thus, an internal power source (such as a disposable battery, a rechargeable battery, etc.) or an external power source (e.g., via a cable connecting to the target device) may be provided to power this type of multi-purpose control device.

[0022] Various other advantages will become apparent to those skilled in the art based on the following detailed description.

[0023] The term "several" as used herein may refer to any positive integer starting from 1, such as 1, 2, or 3.

[0024] The terms "plurality" may each refer to any positive integer starting from two.

[0025] The terms "first," "second," "third," and "fourth" are used herein to distinguish one element from other element(s) and do not confer any special priority or ordering thereon, unless expressly stated otherwise.

[0026] The exemplary embodiments of the invention presented herein should not be construed as limiting the applicability of the appended claims. The verb "comprise" is used herein as a disclosure limitation that does not exclude the presence of unrecited features. The features recited in the various embodiments and, for example, the dependent claims can be freely combined with each other, unless expressly stated otherwise.

[0027] The novel features which are believed to be characteristic of the invention are set forth with particularity in the appended claims, but the invention itself, both as to its structure and its method of operation, together with additional objects and advantages thereof, will best be understood from the following description of specific embodiments when read in connection with the accompanying drawings.

[0028] Some embodiments of the present invention are illustrated by way of example, and not by way of limitation, in the figures of the accompanying drawings. [Brief description of the drawings]

[0029] [Figure 1] 1 illustrates one embodiment of a multi-layer structure according to the present invention. [Diagram 2] 2 shows a cross-sectional side view of a multi-layer structure according to various embodiments of the invention, such as the embodiment of FIG. 1, taken along line AA. [Diagram 3] 1 illustrates one embodiment of a multi-layer structure, specifically an associated knob-defining protrusion with a concave sidewall. [Figure 4] 1 illustrates one embodiment of a multi-layer structure, specifically an associated knob-defining protrusion with a convex sidewall. [Diagram 5] 1 illustrates one embodiment of a multi-layer structure, specifically an associated knob-defining protrusion that includes a saddle surface type sidewall. [Figure 6]13 illustrates one other embodiment of a multi-layer structure, specifically an associated knob-defining protrusion that includes a saddle surface-type sidewall. [Figure 7] 1 illustrates one embodiment of a multi-layer structure, specifically an associated knob-defining protrusion having a regular shape and defining six side walls. [Figure 8] 1 illustrates one embodiment of a multi-layer structure, specifically an associated knob-defining protrusion having an irregular shape and defining five side walls. [Figure 9] 1 illustrates an embodiment of a host device, such as an armrest, that includes an embodiment of a multi-layer structure. [Figure 10] FIG. 2 is a flow diagram of one embodiment of a method in accordance with the present invention. [Figure 11] 1 illustrates a further embodiment of a multi-layer structure according to the present invention, and in particular the associated recess-defining protrusions, in cross-sectional side view. [Figure 12] 12 shows an embodiment of the substrate film of FIG. 11 with associated axonometric sketches. [Figure 13] In particular, an embodiment of a multilayer structure is shown in terms of its potential overall shape in the region of a protrusion of the substrate film that protrudes outwardly from the remaining surrounding structure, i.e., towards the user, establishing a knob, with further material layers of the structure generally following the shape of the protrusion, at least locally. [Figure 14] 14 is a sketch of a cross-sectional side view of the embodiment of FIG. 13 taken along line AA. [Figure 15] In terms of its potential overall shape, an embodiment of a multilayer structure is shown that protrudes inwardly away from the user and use environment of the structure, particularly in the region of a recess-defining protrusion in the substrate film, with further material layers of the structure generally following the shape of the protrusion, at least locally. [Figure 16] 16 shows the embodiment of FIG. 15 in cross-sectional side view along line AA. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0030] Figure 1 illustrates one embodiment of a multi-layer structure according to the present invention at 100. Figure 2 illustrates a cross-sectional side view at 200 of a multi-layer structure according to various embodiments of the present invention, such as the embodiment of Figure 1, taken along line AA depicted in Figure 1.

[0031] The multilayer structure comprises at least one substrate film 202, which is preferably flexible and 3D formable (moldable), such as a thermoformable material. In addition to the film 202, the structure may comprise at least one further (substrate) film 212 of common and / or different material(s) to the material(s) of the film 202. The film 202 advantageously comprises a first side and associated first surface 202a directed towards the environment of use of the structure and towards, for example, a user, or in particular towards the user's hand, finger, stylus or other touch, pointing or gripping element 180 present therein. Furthermore, the film 202 comprises an opposite second side and associated second surface 202b, for example essentially facing the interior of the structure.

[0032] The substrate film 202 and / or the further film 212 or material layers included in the multi-layer structure may comprise at least one material selected from the group consisting of polymers, thermoplastic materials, electrically insulating materials, PMMA (polymethyl methacrylate), polycarbonate (PC), copolyesters, copolyester resins, polyimides, copolymers of methyl methacrylate and styrene (MS resins), glass, polyethylene terephthalate (PET), carbon fibers, organic materials, bio-materials, leather, wood, fibers, fabrics, metals, organic natural materials, solid wood, veneer, plywood, bark, bark, birch bark, cork, natural leather, natural fiber or fabric materials, natural leather, natural cotton, wool, linen, silk, and any combination thereof.

[0033] The thickness of the film 202, and optionally the further film 212, may vary depending on the embodiment and may be only a few tens or hundreds of millimeters, or may be significantly thicker, for example, on the order of a millimeter or a few millimeters.

[0034] Preferably, at least the film 202 and optionally the further film 212 have been treated by thermoforming or other feasible (taking into account the material(s)) forming method to define a local protrusion 101 rising from a plane 220 defined by the surrounding film material. The protrusion 101 may have and define several side walls 104, for example as well as a top surface 201. It 101 is preferably tactile and advantageously visually perceptible by the user from the environment of the structure, creating for example a knob shape that is easy to feel and to pinch. The walls 104 and the corners or edges between the walls 104 and the top surface 201 may be rounded or curved, for example a direct result of the forming method used, such as thermoforming. Alternatively, a concave shape can be created by the protrusion 101 of a multi-layer structure, as shown for example in Figures 11 and 12 and explained in more detail in the associated description.

[0035] In various embodiments, one or more additional layers 203 may be present, at least locally, such as on any of the walls 104, the top 201, and / or the surrounding film. Any additional layer 203 may optionally include, for example, a coating or a film. The material of the material layer may be different from the one of the substrate films 202. It may include, for example, a selected polymer material, optionally with (nano)particles, to provide, among other options, a desired anti-scratch, anti-reflective, reflective, tactile and / or visual effect.

[0036] Item 208 refers to at least one filler layer, preferably provided by molding on film 202, optionally between film 202 and film 212, where the film(s) may be used as insert(s) in an associated mold(s).

[0037] The at least one filling layer may comprise at least one material selected from the group consisting of polymers, organic materials, biomaterials, composite materials, thermoplastic materials, thermoset materials, elastomeric resins, PC, PMMA, ABS, PET, copolyesters, copolyester resins, nylon (PA, polyamide), PP (polypropylene), TPU (thermoplastic polyurethane), polystyrene (GPPS), TPSiV (thermoplastic silicone sulfite), and MS resin.

[0038] Item 206 refers to circuitry provided on substrate film 202, i.e., circuitry provided directly on (or on) the film 202 itself (typically on at least one selected surface thereof) and / or any adjacent or subsequent films, or other material layers, of a multi-layer structure. Circuitry 206 may include, for example, a number of electrical conductors (traces), contact pads, electrodes, and integrated circuits (ICs), such as, for example, sensor drive, readout and / or control circuitry, or control circuitry in general, for UI functionality provided by the structure and / or some other functionality provided by the structure.

[0039] In line with the above, the circuitry 206 may be produced, for example, directly on any one or more of the films 202 (e.g., on surface 202b) and 212 (if present), and / or on other structures, material layers or associated surfaces of the multi-layer structure, by selected method(s), such as printed electronics techniques, optional screen printing or other additional printing, or generally coating techniques. Additionally or alternatively, the circuitry 206 may include some mounted components, such as surface mounted devices (SMDs). Thus, non-conductive and / or conductive adhesives may be utilized to fix the mounted components to the carrier. In some embodiments, the mechanical fixation is implemented or at least reinforced by a non-conductive adhesive material, while solder or other highly conductive (but to a lesser extent, adhesive type) material is used for the electrical connection. Preferably, the circuitry 206 is at least partially, if not completely, provided on the film 202, and optionally on the film 212, prior to 3D shaping of the film(s) (i.e., when the film(s) 202, 212 are still essentially planar or at least more planar), to avoid laborious 3D assembly of electronics on an already 3D shaped carrier. However, embodiments in which the film 202 does not carry any, or at least a substantial amount, of the circuitry 206 are also feasible. In these and other embodiments, for example, a further substrate film 212 or other material layer may still host any selected circuitry 206.

[0040] For example, if capacitive sensing is applied, the sensing electrodes of the circuitry 206 may be configured (sized, positioned, etc.) such that their sensing areas or volumes defined by the associated electric fields are positioned as desired to thereby cover, for example, selected sidewall and / or top areas of the structure and / or other areas that are to be sensed for touch (and / or in some embodiments, non-touch gestures). This type of configuration may be achieved or performed, for example, through the use of simulations or measurements.

[0041] Thus, the circuit 206 may include any of a variety of components, including electronic components, electromechanical components, electro-optical components, radiation emitting components, light emitting components, LEDs (light emitting diodes), OLEDs (organic LEDs), side shooting LEDs or other light sources, top shooting LEDs or other light sources, bottom shooting LEDs or other light sources, radiation detecting components, light detecting or light sensitive components, photodiodes, phototransistors, photovoltaic devices, sensors, micromechanical components, switches, touch switches, touch panels, proximity switches, touch sensors, air sensors, temperature sensors, pressure sensors, moisture sensors, gas sensors, proximity sensors, capacitive switches, capacitance sensors, projected capacitance sensors or switches, single electrode capacitance switches or The sensor may include at least one component selected from the group consisting of a sensor, a capacitive button, a multi-electrode capacitive switch or sensor, a self-capacitance sensor, a mutual capacitance sensor, an inductive sensor, a sensor electrode, a micromechanical component, a UI element, a user input element, a vibration element, a sound generating element, a communication element, a transmitter, a receiver, a transceiver, an antenna, an infrared (IR) receiver or transmitter, a wireless communication element, a wireless tag, a tag reader, a data processing element, a microprocessor, a microcontroller, a digital signal processor, a signal processor, a programmable logic chip, an ASIC (application specific integrated circuit), a data storage element, an electronic subassembly, a light directing element, a light guide, a lens, and a reflector.

[0042] Preferably, one or more of the side walls 104 and / or top portion 201 are associated with or provided with circuitry 206, such as electrodes for capacitive sensing, or other sensing elements that may be connected to control circuitry, such as a microcontroller, microprocessor, or integrated IMSE node (a part-like integrated IMSE subassembly with its own substrate, electronics, fillers, and optional shell), and preferably provided outside the structure, such as within a volume (V) that is essentially defined, for example, by the shape of the protrusion 101 or elsewhere within the structure, and / or within a host or external device. Each wall 104, advantageously its inner surface 202b, may be associated with a single sensing element as well as multiple sensing elements, such as electrodes arranged in a desired configuration, such as a row (e.g., laterally) or matrix configuration. Alternatively or additionally, the sensing elements may be sized and positioned, and the sensing or reading circuitry may generally be configured by one of ordinary skill in the art, to cover only a selected larger area or areas, optionally allowing for more detailed sensing of the user's finger, for example, over an area where the spatial resolution is more precise than over the entire covered area / area.

[0043] As already mentioned above, the structure may be, and in many preferred usage scenarios will be, connected to an external system or device 230, such as a host device for the structure, which is shown in FIG. 2 by a connector, e.g., an electrical connector or connector cable 230a, which may be attached to the structure and its elements, such as circuitry 206, in a selected manner, e.g., communication and / or power supply manner.

[0044] Item 210 refers to a possible host surface or structure for the multi-layer structure contemplated herein. In some embodiments, item 210 may be part of the host device of the multi-layer structure, or it 210 may be an intermediate element. A person skilled in the art will readily understand that the connector 203a, or in general the connection between the electronics of the multi-layer structure and the host / external device, may be achieved through item 210 instead of or in addition to its side. The material of item 210 may include any material deemed advantageous, such as any of the materials mentioned above (e.g., plastic, metal, organic material or natural material).

[0045] Item 140 refers to one or more possible visual indicators provided within the structure, for example on the film 202. These indicators can indicate to the user the location of gesture sensing areas, guidance on how to provide input, feedback in response to detected user input, the status of the UI or a particular feature of the UI, or a host / connected external device. The indicators can be static, such as graphics printed or otherwise generated on a host surface, such as the film 202, a possible coating 203, or a further layer of the structure. Additionally or alternatively, the indicators may have a time-dynamic component. For example, with embedded light sources such as (O)LEDs, the structure can be configured to provide dynamic visual information to the user (dimming, on / off control, etc.). For example, if the sidewall 104 includes several light sources, e.g., as part of the circuitry 206 or as a translucent / transparent material that emits light from below the light sources, the light sources may be controlled to indicate to the user a detected or pending user input, for example, by momentarily lighting up the light(s) in a selected sequence (e.g., a row of light sources / indicators activated one at a time in a spatially sequential sequence indicating a pending / detected finger swipe).

[0046] Item 207 refers to at least one possible connection element, such as a conductive pin, rod or wire, extending between the different sides of the fill layer 207 and, for example, the circuitry 206 provided on each side. The connection provided may alternatively or additionally be wireless.

[0047] Item 150 is a dot sketch illustrating user inputs that may be suitably provided and detected by structures according to various embodiments of the present invention. In addition to taps and 2D swipe activities, continuous gestures such as swipes on some surfaces, such as sidewall 104, may be detected and associated with a predefined response. As contemplated herein, the UI solution proposed herein may establish part of a larger ensemble of some structures and / or devices, for example, considering in-vehicle electronics, so that UI inputs detected by or through the multi-layer structure may be indicated, or associated responses may be indicated, including, for example, control actions provided using other at least functionally connected external devices or so-called host devices, in addition to or instead of the multi-layer structure itself.

[0048] In various embodiments, the protrusion 101, or generally the multi-sided knob shape defined by the protrusion 101 itself, comprises an upper portion 201, a cross section and / or a 2D protrusion, at least one of which preferably has a substantially squircle shape.

[0049] In these and other embodiments, the protrusion and multi-layer structure generally may be configured for at least touch-based gesture detection by utilizing circuitry 206 via at least two, and preferably each, of the multiple side walls of the protrusion 101, preferably via remotely positioned sensing elements such as electrodes and associated additional circuitry 206 directly attached / provided (e.g., additively printed) on the wall and / or on the multi-layer structure.

[0050] In various embodiments, the multi-sided knob or recess shapes defined by the protrusions in the multi-layer structure may include the general shape of a shoob (spherical cube) or a squirrel ellipsoid. The general or dominant shape may be modified, for example, with sloping and / or curved sidewalls 104 and / or a flat, angled, or curved top 201.

[0051] In various embodiments, the multi-sided knob shape defined by the protrusions may include, for example, any of three, four, five, six, seven, or eight touch-sensitive sidewalls within the plurality of sidewalls.

[0052] Preferably, the knob or recess shape has at least two, and preferably each, rounded corners between adjacent side walls 104, and optionally also rounded transitions between side walls 104 and top 201. A rounded shape may be preferred and achievable, and therefore more practical in terms of the materials and processes used, e.g., thermoforming or other 3D forming.

[0053] In various embodiments, at least one sidewall of the plurality of sidewalls 104, and preferably each of them, defines a curved surface, optionally a convex and / or concave surface, in the lateral L direction and / or longitudinal T direction of the sidewall.

[0054] In FIG. 3, at 300, an embodiment of a multi-layer structure is shown, specifically, an associated knob-defining projection including a concave sidewall.

[0055] In FIG. 4, at 400, an embodiment of a multi-layer structure is shown, specifically, an associated knob-defining projection including a convex sidewall.

[0056] Preferably, at least one side wall essentially defines a saddle surface, which is preferably convex in the lateral (L) direction of the side wall and concave in the longitudinal (T) direction, or vice versa.

[0057] FIG. 5 illustrates, at 500, one embodiment of a multi-layer structure, specifically an associated knob-defining projection that includes a saddle surface-type sidewall (latitudinally concave, longitudinally convex).

[0058] FIG. 6 illustrates at 600 one other embodiment of a multi-layer structure, specifically an associated knob-defining projection that includes saddle surface-type sidewalls (latitudinally convex, longitudinally concave).

[0059] In various embodiments, the protrusion 101 may have a substantially flat or curved upper portion 201 that is optionally substantially squircle-shaped and whose diameter is optionally on the order of magnitude of about 8 centimeters or less, more preferably about 7 centimeters or less, and most preferably about 4 to about 7 centimeters. In some other embodiments, other dimensions may also be utilized.

[0060] Depending on the embodiment, the upper portion 201 may be monolithic with any one or more of the side walls 104, for example as shown in FIG. 2, or it may be a separate piece of material in nature, optionally of a different material, attached or created on the protruding walls that define the sides, for example using adhesive and / or suitable mechanical fastening elements (screws, bolts / nuts, snap fasteners, etc.).

[0061] In some embodiments, top portion 201 (or a layer 203 above it) may implement a touch-sensitive surface (e.g., a "button" function), for example, by means of capacitive sensing electrodes thereunder and associated further circuitry 206. In some embodiments, a touchpad or more versatile user input functionality may be implemented as well.

[0062] In various embodiments, the height of the protrusions can be, for example, about 4 centimeters or less, preferably between about 1 and 3 centimeters. In some other embodiments, other dimensions can also be utilized.

[0063] In various embodiments, the length of the side walls in the plurality of side walls is about 6 centimeters or less, preferably about 3 centimeters to about 6 centimeters in the lateral direction L, and / or about 4 centimeters or less, preferably between about 1 centimeter and 3 centimeters in the longitudinal direction T. In some other embodiments, other dimensions may be utilized.

[0064] As will be appreciated by those skilled in the art and as already mentioned above, the dimensions may be adjusted for each embodiment based, for example, on the anticipated usage scenario, including, for example, a particular size user (child vs. adult, with apparent differences in finger range and size) and the type of input to be registered via the UI. In some embodiments, the dimensions may be selected (scaled up), for example, to support users wearing different handwear.

[0065] As contemplated herein, the multi-layer structure including the electronics and the knob shape established by the protrusions may be configured to detect several different gestures, preferably at least one touch type selected from the group consisting of radial swipes (successive corner wraps), lateral swipes, taps, or multiple taps, optionally within a selected time period and / or within a selected time period between successive taps, parallel gestures such as pinch in, pinch out, swipes optionally including at least two fingers, and opposing gestures such as swipes optionally involving at least two fingers.

[0066] The detection logic or mapping logic may be encoded in the circuit 206 or external electronics at least functionally connected to the circuit 206, for example, via the connector 230a. For example, if several adjacent or otherwise configured touch detection elements, such as capacitive electrodes, indicate a touch in a temporal sequence, it may be converted into a (sequential) sweep input detected by the detection logic, and an associated linked control action, potentially activating or deactivating a function in the host or connected external device or system, may then be triggered in response. In general, the association between a particular type of touch (e.g., a lateral sweep, a tap, a series of different actions, etc.) and a control action may be context-dependent in various ways. The association may be configured, for example, as application or application view specific, and / or may depend on some further conditions, such as a sensor or other measurable or configurable value (acceleration, speed or velocity, temperature, pressure, lighting, orientation, time, location, etc.). However, feedback regarding the detected input, and optionally feedback indicative of the recognized input type, may be provided via the multi-layer structure itself, for example using visual feedback such as lighting and / or haptic feedback, for example if a vibration motor or other vibrating element is provided within the multi-layer structure as part of the circuitry 206.

[0067] As mentioned above, the multi-layered structure may comprise several light sources, such as LEDs. These light sources may be configured to have lighting functions, for example, based on decorative or informative (suggestive) motives, and the light sources may be configured to illuminate the environment and / or surfaces of the structure, such as (part of) the sidewall 104 or the top 201, which are deemed ready or not ready to receive input, or other elements of the structure itself. Also, decorative shapes or graphics (such as paints, inks, surface reliefs, masks, masking pattern(s), and translucent / transparent materials) placed within the structure may be illuminated. Additionally or alternatively, the light source(s) may be configured to indicate the detected touch, and optionally the location and / or nature of the detected touch, further optionally through a multi-sided 3D knob or recess shape defined by the protrusions.

[0068] In various embodiments, the control actions contemplated herein may include at least one action selected from the group consisting of triggering a control signal, light control, light control in a multi-layer structure, exterior light control, vehicle feature control, host device feature control, air conditioning control, chassis control, multimedia control, window control, menu feature access, cursor motion, feature selection, feature activation, menu feature selection, scroll action, menu item scroll action, and zoom.

[0069] In some embodiments, the multi-layer structure may be configured to detect at least partially non-contact 2D or 3D gestures, preferably on the shape of a multi-sided knob or recess, and more preferably to detect the type of gesture, e.g., capacitive sensing may also be utilized for this purpose.

[0070] As also suggested herein, in various embodiments, the different material(s) of the substrate film 202 and / or any of the further layer(s) or elements, such as the infill 208, the layer 203, or the further film 212, may be at least partially optically not substantially opaque or essentially transparent, but at least translucent, considering a given wavelength, e.g., the visible spectrum. The associated element(s) optionally defining at least a portion of the exterior (surface) of the multilayer structure or at least visible or otherwise perceptible through it, may be provided with some visually distinguishable, decorative / aesthetic and / or beneficial features, such as graphic patterns and / or colors thereon or therein. The materials used may be at least partially, i.e. at least in places, optically substantially transparent to radiation, such as visible light emitted by electronics. The transmittance may be, for example, about 80%, 85%, 90%, 95% or more.

[0071] In various embodiments, selected features including, for example, graphics, coloring, or other visual features, may be provided on any of the interior surfaces or layers of the multi-layer structure, such that different impacts, friction, chemicals, etc. that may easily damage, for example, painted, printed, or attached surface features, do not affect or reach the embedded / non-surface and potentially sealed features.

[0072] 7 shows at 700 an embodiment of a multi-layer structure, specifically an associated knob-defining protrusion, having a regular, highly symmetrical shape and defining six sidewalls. In other possible embodiments, the number of sidewalls may be different, but the structure remains regular.

[0073] 8 illustrates an embodiment of a multi-layer structure at 800, specifically an associated knob-defining protrusion having a more irregular shape and defining five sidewalls. In other possible embodiments, the shape remains generally irregular and the number of sidewalls may vary naturally.

[0074] FIG. 9 shows at 900 an embodiment of a host device, such as an armrest, that includes an embodiment of a multi-layer structure, such as the embodiment of FIGS.

[0075] FIG. 10 includes, at 1000, a flow diagram of one embodiment of a method in accordance with the present invention.

[0076] At the beginning of the method for manufacturing a multi-layer structure, a start-up stage 1002 may be performed. During start-up, necessary tasks such as selection, acquisition, calibration of materials, parts and tools, as well as other configuration tasks may be performed. Special care must be taken to ensure that the selection of the individual elements and materials works together and survives the selected manufacturing and installation process, which is preferably checked naturally beforehand based on the manufacturing process specifications and part data sheets, or for example by inspecting and testing generated prototypes. Thus, the equipment used, such as molding, IMD (in-mold decoration), lamination, bonding, (thermo)forming, electronics assembly, cutting, drilling and / or printing equipment, may be brought up to an operational state in this stage.

[0077] In 1004, at least one, optionally flexible, substrate film of plastic or other material, for example for housing electronics, is obtained. The substrate film may initially be substantially flat or may be, for example, curved. The substrate film may be at least mainly of electrically substantially insulating material(s). A prefabricated element, for example a roll or sheet plastic film, may be obtained for use as substrate material. In some embodiments, the substrate film itself may be produced in-house by first forming the selected starting material(s) using a mold and / or forming device or other method. Optionally, the substrate film may be further processed at this stage. It may be provided with, for example, holes, notches, recesses, cuts, etc.

[0078] At 1006, sensing elements, such as conductor lines (traces), electrodes, and / or some conductive elements defining contact areas for building a circuit design are provided on one or more of the included substrate film(s), on either or both sides thereof, preferably by one or more additive techniques of printed electronics technology. For example, screen, inkjet, flexographic, gravure, or offset lithographic printing can be applied by suitable printing device(s). In some cases, subtractive or semi-additive processes can also be utilized. Furthermore, further operations of applying to the film(s) can now be performed, for example involving printing or generally providing graphics, visual indicators, optical elements, etc. thereon.

[0079] In various embodiments, the conductive elements may include at least one material selected from the group consisting of conductive inks, conductive nanoparticle inks, copper, steel, iron, tin, aluminum, silver, gold, platinum, conductive adhesives, carbon fibers, alloys, silver alloys, zinc, brass, titanium, solder, and any parts thereof. The conductive materials used may be optically opaque, semi-transparent, and / or transparent at desired wavelengths, such as visible light, such that radiation, such as visible light, is masked or reflected therefrom, absorbed therein, or allowed to pass therethrough.

[0080] At 1008, one or more typical prefabricated components, including various SMD and other electronic components, may be attached to the contact areas on the film(s), for example by solder and / or adhesive. A suitable pick-and-place or other attachment device may, for example, be utilized for that purpose. Alternatively or additionally, printed electronics techniques may be applied to actually fabricate at least a portion of a component, such as an OLED, directly on any one or more of the included film(s). Thus, the execution of items 1006, 1008 to provide the multilayer structure with the desired circuitry may overlap in time, as will be understood by those skilled in the art. However, the installed components may include, for example, one or more connectors.

[0081] For completeness considering the provision of circuits and components to the structure, item 1009 refers to the possible attachment of one or more subsystems or "subassemblies" that may incorporate an initially separated secondary substrate provided with electronics such as IC(s) and / or various components. At least a portion of the electronics of the multi-layer structure may be provided to the substrate film(s) via such a subassembly. Optionally, the subassembly may be at least partially overmolded with a protective plastic layer before attachment to the main substrate. This may be the case, for example, for IMSE nodes such as the components mentioned above. For example, adhesives, pressure, and / or heat may be used for mechanical bonding of the subassembly to the primary (host) substrate. Solder, traces, and conductive inks are examples of applicable options for providing electrical connections between the elements of the subassembly and with the remaining electrical elements on the primary substrate. Item 1009 may also be performed, for example, on item 1006 or 1010. Its indicated locations are mainly exemplary only.

[0082] In some embodiments, prior to or during the forming step 1012, the substrate film(s), which preferably already contains at least part of the circuit design, e.g. (printed) conductive elements and optionally electronic components, and / or connectors (see double curved arrow emphasizing that forming can alternatively or additionally take place, e.g. between items 1006-1008, or even before item 1006), can be formed 1010, e.g. using thermoforming or cold forming, to assume a desired shape, e.g. at least locally three-dimensional (essentially non-planar) shape including knobs or recess-defining protrusions as described in more detail herein. For that purpose, applicable forming devices such as thermoforming machines can naturally be utilized. Additionally or alternatively, at least some forming can also take place after forming, if the already established multi-layer stack is designed to withstand such processing.

[0083] At 1012, at least one plastic fill layer, preferably a thermoplastic or thermosetting layer, is produced, preferably molded, such as by injection molding, on the substrate(s), preferably to at least partially fill the volume defined by the protrusion shape (more applicable to knob embodiments) and at least partially embed the circuitry and, optionally, further parts or elements of the multi-layer structure (applicable to both knob and recess embodiments). The molding material(s) may be provided using several molding steps or shots or via a single step, and the molding material can optionally flow through the film from one side of it to the other side, for example, via holes prepared therein or by penetrating the substrate material itself (e.g., through thinned / thinner parts). The molding material(s) can, for example, be substantially electrically insulating.

[0084] In practice, at least one substrate film, already equipped with some further features such as circuits, can be used as an insert in the injection molding process applying at least one molding machine. If two films are used, both of them can be inserted in each half mold so that at least between them the plastic layer is injected. Alternatively, a second film can be subsequently attached to the assembly of the first film and the plastic layer by a suitable lamination technique.

[0085] Concerning the resulting overall thickness of the obtained laminated multilayer structure (excluding protrusions whose dimensions are described herein), it depends, for example, on the materials used and the associated minimum material thickness that provides the necessary strength in view of the manufacturing and subsequent use. These aspects need to be considered separately. For example, the overall thickness of the structure can be on the order of a few millimeters, although significantly thicker or thinner embodiments are also feasible.

[0086] Item 1014 refers to possible additional tasks, such as post-processing tasks. Further layers or generally features may be added to the multi-layer structure by molding, lamination, or suitable coating (e.g., deposition) procedures. The layers may be of protective, instructional and / or aesthetic value (graphics, colors, shapes, text, numerical data, etc.) and may contain, for example, textile, leather, or rubber materials instead of or in addition to further plastics. Additional elements, such as electronics, may be placed on the outer surface(s) of the structure, such as the outer surface of the substrate or a molding layer thereon, depending on the embodiment. Shaping / cutting may be performed. If provided with a connector, the connector may be connected to a desired external connection element, such as an external device, system, or structure, e.g., an external connector of a host device. For example, these two connectors together may form a plug-and-socket type connection and interface.

[0087] At 1016, method execution ends.

[0088] In the embodiment 1100 shown in FIG. 11, the protrusion 101 established in the film 202 is essentially flipped 180 degrees from that of the previous embodiment, and is therefore configured to protrude away from the environment of the multilayer structure and the user therein (finger, stylus, etc.) and therefore towards the interior of the multilayer structure, unlike the previous embodiment where the protrusion was essentially directed towards the environment and protruded away from the remaining surrounding substrate film and the overall multilayer structure. Thus, now the protrusion 101 of the film 202 defines a recess in the multilayer structure that still has vertical or inclined side walls, instead of an outwardly protruding knob shape. Even if there is a further layer 203, such as film(s), coating(s), and / or filler, on top of the formed recess, the recess is still preferably accessible and present on the outer surface of the overall structure. Thus, the top 201 of the protrusion established in the film 201 may simultaneously define the bottom 1101 of the recess defined by the protrusion 101 in relation to the overall multilayer structure. The dimensions may be selected to provide sufficient clearance for a user's finger(s) or stylus 180 to enter the recess to provide user input, for example by touching the wall 104 or the bottom 1101 using a tap and / or swipe.

[0089] In this and similar embodiments, the volume defined or limited by the surrounding substrate film portion and the plane of the actual protrusion shape 101 and thus defining the aforementioned recess for the user to enter and interact with using finger(s) and typically primarily the fingertip or stylus does not necessarily (although it still can) accommodate additional elements such as, for example, electronics 206, which may be very conveniently configured in many scenarios, on the second side 202b of the film 202, for example, essentially adjacent to the recess shape (e.g., to the side and / or below) and / or far away from it, as shown in the figure. Thus, if desired, the sidewalls and recess bottoms facing and limiting the volume on the first side 202a of the film 201 may be kept free from further elements. In many practical use scenarios, the volume defined by the recess is generally accommodated by a fluid such as air of the use environment, which is then possibly displaced by the user's finger(s) or stylus.

[0090] In general, the various considerations and notes provided herein with respect to the aforementioned embodiments and their features (materials, dimensions, shapes including protrusion shapes and sidewall shapes, additional elements, functionality, etc.), as well as the different general principles of the present invention, remain applicable mutatis mutandis in relation to the embodiment of FIG. 11, as will be understood by those skilled in the art.

[0091] In some embodiments, even a combination of outward (knob) and inward (recess) features may be provided in the multi-layer structure and, optionally, in the same substrate film. For example, a larger recess feature may even integrate a smaller knob feature, or a larger knob feature may include a smaller recess feature, or the features may be positioned adjacently.

[0092] 12 illustrates at 1200 an embodiment of the substrate film of FIG. 11 with associated axonometric sketches. The recesses established may be of different shapes, as in the case of the corresponding knob shapes contemplated herein. For example, an otherwise substantially similar, but inverted shape may be utilized. The case illustrated herein serves only as one possible example.

[0093] Figure 13 shows at 1300 an embodiment of a multi-layer structure in terms of its potential overall shape, particularly in the region of the protrusions 101 of the substrate film 202. Figure 14 shows at 1400 a sketch of a cross-sectional side view of the embodiment of Figure 13 taken along line AA.

[0094] In the embodiment shown, the protrusion 101 protrudes and extends outward from the remaining surrounding structure, i.e. towards the user in the environment of use, thereby establishing a knob shape therein, as previously described with reference to various other embodiments, but now some further material layers of the structure are configured to generally follow the shape of the protrusion as well. Thus, a similar knob shape created by the infill 208 and, optionally, by further layers such as the film 212 (if present) within the structure can be identified. The overall thickness of the actual material layers of the structure can thereby be conveniently configured to be substantially constant even at the location(s) of the protrusion(s) 101, as shown.

[0095] Figure 15 shows an embodiment of the multi-layer structure at 1500, particularly in terms of its potential overall shape in the region of the recess-defining protrusions 101 of the substrate film 202, so that further material layers of the structure will generally follow the shape of the protrusions, projecting inwardly from the user and environment of use of the structure. Figure 16 shows the embodiment of Figure 15 in a cross-sectional side view at 1600 along line AA.

[0096] Thus, in the embodiments of Figures 13-14 and 15-16, the overall multi-layer structure is one in which one or more adjacent and subsequent material layers are configured to generally follow the essentially undulating shape of the substrate film 202 at the locations of knob or recess type protrusions 101 established therefrom. A substantially constant overall thickness of the structure, as jointly established by the included material layers, can be achieved as a result, if desired. Still, in terms of the overall multi-layer structure, a protrusion on one side of the overall structure can be configured with a recess on the opposite side.

[0097] This approach differs from the previously described embodiments of Figures 2 and 11, for example, in which one or more further layers of the multi-layer structure (e.g., infill 208 or film 212) do not follow the shape of the substrate 202, at least generally (on both sides) at the location of the protrusion 101. Instead, the layers were essentially configured to have a substantially planar surface (see, for example, the bottom surfaces of layers 208, 210, 212 in associated Figures 2 and 11) at least opposite to that facing the protrusion 101, although other, potentially more complex, non-planar layer and surface shapes are equally feasible as will be appreciated by those skilled in the art.

[0098] Otherwise, what is described in this specification, taking into account other embodiments, including those shown in Figures 1-12, is also applicable in connection with the embodiment of Figures 13-16, as would be readily understood by one of ordinary skill in the art.

[0099] The scope of the present invention is determined by the appended claims and their equivalents. Those skilled in the art will appreciate that the disclosed embodiments have been constructed for illustrative purposes only, and that other arrangements applying many of the principles described above can be readily prepared to best suit each potential usage scenario.

Claims

1. 1. A monolithic functional multi-layer structure (100, 200, 300, 400, 500, 600, 700, 800, 1100, 1200, 1300, 1400, 1500, 1600) for building a gesture UI (user interface), comprising: a flexible 3D formable substrate film (202) comprising a first surface (202a) for facing towards the environment of the multilayer structure and a user therein, and an opposite second surface (202b) facing towards the interior of the multilayer structure, wherein the first surface (202a) and the second surface (202b) and the remaining material of the substrate film (202) therebetween extend from a plane (220) of the surrounding substrate film material and locally define three-dimensional protrusions (101) formed from the locally stretched and shaped material of the substrate film (202), the protrusions (101) comprising a plurality of substantially vertical or inclined, optionally at least locally curved, sidewalls (104) perceptible by touch; a circuit (206) provided on the substrate film (202), the circuit (206) comprising several conductive traces, electrodes, and / or components configured to detect contact on two or more of the plurality of side walls (104), preferably on the top (201) of the protrusion (101); and at least one filler layer (208), preferably of a thermoplastic filler material, disposed on said substrate film (202), optionally molded or cast, to at least partially embed said circuitry (206).

2. 2. The structure of claim 1, wherein the circuitry (206) is at least partially contained by a volume (V) defined by the projection shape and the plane.

3. The structure of any one of claims 1 to 2, wherein said at least one filler layer (208) at least partially fills said volume (V) defined by said protrusion shape and said plane.

4. (100, 200) A structure according to claim 1, wherein said projection (101) defines a preferably continuous multi-sided knob extending outward from said surrounding multi-layer structure.

5. 2. The structure of claim 1, wherein the protrusion (101) comprises a top (201), cross section and / or 2D protrusion having a substantially squircle shape.

6. (1100, 1200) The structure of claim 1, wherein the protrusions (101) define preferably continuous multi-sided recesses within the multilayer structure, the bottom (1101) of the multilayer structure being preferably established by the tops (201) of the protrusions (101).

7. 2. The structure of claim 1, wherein the protrusions have the general shape of a shoob (spherical cube) or a squirrel ellipsoid, optionally modified with sloping and / or curved sidewalls and / or a planar, angled, or curved top portion (201).

8. 2. The structure of claim 1, wherein the protrusion comprises three, four, five, six, seven, or eight touch-sensitive side walls within the plurality of side walls (104), preferably with rounded corners between at least two, and preferably each, adjacent side wall, and optionally with a transition between the side wall and a connecting top of the protrusion (201, 1101) that is also rounded.

9. 2. The structure of claim 1, wherein at least one sidewall of said plurality of sidewalls (104), preferably each of them, defines a curved, optionally convex and / or concave, surface in a lateral (L) and / or longitudinal (T) direction of said sidewall.

10. 10. The structure of claim 9, wherein the at least one side wall essentially defines a saddle surface that is preferably convex in a lateral (L) direction and concave in a longitudinal (T) direction of the side wall, or vice versa.

11. 2. The structure of claim 1, wherein the protrusions are optionally substantially squircle-shaped and have a substantially flat or curved upper portion (201) whose diameter is optionally no greater than about 8 centimeters, more preferably no greater than about 7 centimeters, and most preferably on the order of magnitude of about 4 to about 7 centimeters.

12. 2. The structure of claim 1, wherein the height of the protrusions is about 4 centimeters or less, preferably about 1 to 3 centimeters.

13. 2. The structure of claim 1, wherein a length of the side walls within the plurality of side walls is about 6 centimeters or less, preferably about 3 to about 6 centimeters, in the lateral direction (L) and / or about 4 centimeters or less, preferably about 1 to 3 centimeters, in the longitudinal direction (T).

14. 2. The structure of claim 1, comprising at least one material layer (203), optionally comprising a coating or film, on the first surface (202a) of the substrate film (202), the material of the material layer preferably being different from one of the substrate films (202).

15. 2. The structure of claim 1, further comprising a further film (212) on a side of the filler layer (208) opposite the side of the substrate film (202), the further film (212) optionally configured to house at least a portion of the circuitry (206).

16. 10. The structure of claim 1, wherein the substrate film and / or any additional film or material layers comprise at least one material selected from the group consisting of polymers, thermoplastic materials, electrically insulating materials, PMMA (polymethyl methacrylate), polycarbonate (PC), copolyesters, copolyester resins, polyimides, copolymers of methyl methacrylate and styrene (MS resins), glass, polyethylene terephthalate (PET), carbon fibers, organic materials, biomaterials, leather, wood, fibers, fabrics, metals, organic natural materials, solid wood, veneer, plywood, bark, birch bark, cork, natural leather, natural fiber or fabric materials, naturally grown materials, cotton, wool, linen, silk, and any combination thereof.

17. 10. The structure of claim 1, wherein the at least one filler layer comprises at least one material selected from the group consisting of polymers, organic materials, biomaterials, composite materials, thermoplastic materials, thermoset materials, elastomeric resins, PC, PMMA, ABS, PET, copolyesters, copolyester resins, nylon (PA, polyamide), PP (polypropylene), TPU (thermoplastic polyurethane), polystyrene (GPPS), TPSiV (thermoplastic silicone sulfite), and MS resin.

18. The circuit (206) may include any of the following: electronic components, electromechanical components, electro-optical components, radiation emitting components, light emitting components, LEDs (light emitting diodes), OLEDs (organic LEDs), side shooting LEDs or other light sources, top shooting LEDs or other light sources, bottom shooting LEDs or other light sources, radiation detecting components, light detecting or light sensitive components, photodiodes, phototransistors, photovoltaic devices, sensors, micromechanical components, switches, touch switches, touch panels, proximity switches, touch sensors, air sensors, temperature sensors, pressure sensors, moisture sensors, gas sensors, proximity sensors, capacitive switches, capacitance sensors, projected capacitance sensors or switches, single electrode capacitance switches or sensors, 10. The structure of claim 1, comprising at least one component selected from the group consisting of a capacitive button, a multi-electrode capacitive switch or sensor, a self-capacitance sensor, a mutual capacitance sensor, an inductive sensor, a sensor electrode, a micromechanical component, a UI element, a user input element, a vibration element, a sound generating element, a communication element, a transmitter, a receiver, a transceiver, an antenna, an infrared (IR) receiver or transmitter, a wireless communication element, a wireless tag, a radio tag, a tag reader, a data processing element, a microprocessor, a microcontroller, a digital signal processor, a signal processor, a programmable logic chip, an ASIC (application specific integrated circuit), a data storage element, an electronic subassembly, a light guiding element, a light guiding plate, a lens, and a reflector.

19. 2. The structure of claim 1, configured to detect at least one touch type selected from the group consisting of: a radial swipe, a lateral swipe, a tap, multiple taps optionally within a selected time period and / or within a selected time period between successive taps, a pinch in, a pinch out, parallel gestures such as a swipe, optionally with at least two fingers, and an opposite gesture such as a swipe, optionally with at least two fingers.

20. 10. The structure of claim 1, configured to perform a selected control action in response to the detected touch, the control action being associated with a recognized type of the touch through mapping logic or data.

21. 21. The structure of claim 20, wherein the control action comprises at least one action selected from the group consisting of: triggering a control signal, a light control, a vehicle feature control, a host device feature control, an air conditioning control, a chassis control, a multimedia control, an appliance control, a window control, a menu feature access, a cursor motion, a feature selection, a feature activation, a menu feature selection, a scroll action, a menu item scroll action, and a zoom.

22. 10. The structure of claim 1, further comprising several light sources, such as LEDs, preferably configured to indicate the detected touch and optionally the nature of the detected touch, optionally through a multi-sided knob or recessed shape defined by the protrusions.

23. 2. A structure according to claim 1, preferably configured to detect at least partially contactless 2D or 3D gestures on said protrusions, and more preferably to detect said type of said gesture.

24. A host device (900) comprising the structure of claim 1, optionally comprising at least one of a console, a vehicle console, a door, a roof panel, a multimedia device, a home appliance, a personal communication device, or a control device.

25. 25. The host device of claim 24, comprising an armrest provided with arm or wrist sensors, such as capacitive, resistive, optical and / or pressure sensors, and configured to change the operational state of the structure based on data provided by the sensors, and optionally configured to adapt or activate touch sensing in response to detecting the presence of a user's arm or wrist on the armrest.

26. 10. Use of a multi-layer structure or a host device according to claim 1 in obtaining user input and, optionally, initiating control actions based on said user input.

27. A method (1000) for producing an integral multi-layer structure, comprising: obtaining a substrate film (1004) comprising a formable, optionally thermoformable, material, and further comprising a first surface (202a) for facing towards the environment of said structure and a user therein, and an opposite second surface (202b) for facing towards the interior of said structure; providing circuitry (1006, 1008) on said substrate film, preferably using printed electronics technology and / or selected attachment techniques; three-dimensionally forming the substrate film (1010) such that the first surface (202a) and the second surface (202b) and the remaining material of the formed substrate film (202) therebetween locally define three-dimensional (3D) protrusions (204) extending from a plane (220) of the surrounding substrate film material, the protrusions (204) comprising a plurality of substantially vertical or inclined, optionally at least locally curved, sidewalls (204) perceptible by touch; forming the circuit three-dimensionally with several conductive traces, electrodes, and / or components configured on the substrate film to detect touch on two or more of the side walls, preferably on the top of the protrusion (201); and disposing, optionally by injection molding or casting, at least one filling layer, preferably of a thermoplastic filling material (1012), on said substrate film to at least partially embed said circuitry and, optionally, a volume (V) defined by the protrusion shape and said plane, wherein said circuitry is optionally at least partially contained by said volume.

28. 28. The method of claim 27, wherein the protrusion comprises a top portion (201), a cross section having a substantially squircle shape and / or a 2D protrusion.

29. (100, 200) A method according to any one of claims 27 to 28, wherein the protrusion (101) preferably defines a continuous multi-sided knob (100, 200) extending outwardly from the surrounding multi-layer structure.

30. (1100, 1200) A method according to any one of claims 27 to 28, wherein the protrusions (101) define preferably continuous multi-sided recesses in the multilayer structure, the bottom (1101) of the multilayer structure being preferably established by the tops (201) of the protrusions (101).

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