Console with a Grounding Decorative Ring

Abstract

The present disclosure provides a "console with a grounded decorative ring". A vehicle console includes a decorative ring that is sleeved around the periphery of a housing. The decorative ring includes a polymeric material and is conductive and grounded. A proximity switch assembly is held in the housing. The proximity switch assembly includes a proximity sensor that is close to a sensing pad for generating an activation field. The sensing pad is close to the decorative ring.

Description

Technical Field

[0001] The present invention generally relates to consoles, and more particularly to consoles having a grounded decorative ring. Background Art

[0002] Consoles, such as consoles containing vehicle controls, provide a location for activation buttons for lights, climate control settings, audio systems, and other vehicle functions. Some activation buttons can be field - enabled proximity switches. Consoles sometimes include visually appealing decorative trim. Some decorative trim components can be conductive.

[0003] Console design considerations include material selection based on material properties such as conductivity, resistivity, melting point, ease of manufacture, and economy. In addition, console design considerations include the arrangement of conductive trim components relative to field - enabled components. There is always a need to improve console design, functionality, and material selection. Summary of the Invention

[0004] In one aspect of the present invention, a vehicle console includes a decorative ring that is sleeved around the perimeter of a housing. The decorative ring is made of a polymeric material and is conductive and grounded. A proximity switch assembly is held in the housing. The proximity switch assembly includes a proximity sensor that is close to a sensing pad for generating an activation field. The sensing pad is close to the decorative ring.

[0005] Embodiments of the first aspect of the present invention may include any one or combination of the following features:

[0006] · A light, wherein the proximity switch assembly is disposed on the light;

[0007] · The housing includes a perforated cover plate;

[0008] · The sensing pad includes a lens disposed in the hole;

[0009] · The proximity sensor is a capacitive sensor;

[0010] · The decorative ring surrounds the sensing pad;

[0011] · The decorative ring is electrically connected to a conductive support, and wherein the conductive support is electrically connected to a PCB;

[0012] · The decorative ring includes a heat - melt pin that is connected to the conductive support;

[0013] · The housing is a first polymeric material, while the decorative ring is a second polymeric material;

[0014] · The second polymeric material is acrylonitrile - butadiene - styrene (ABS) that includes from about 0.5% to about 2% by volume of multi - walled carbon nanotubes and from about 4% to about 6% by volume of high aspect - ratio carbon black;

[0015] ·The surface resistivity of acrylonitrile butadiene styrene (ABS) containing approximately 0.5% to approximately 2% by volume of multi-walled nanotubes and approximately 4% to approximately 6% by volume of high aspect ratio carbon black is approximately 0.8x10 5 ohm / sq to approximately 1.2x10 5 ohm / sq; and / or

[0016] ·The housing and the decorative ring are made during a bi-injection molding process.

[0017] According to another aspect of the present invention, a housing assembly for a proximity sensor includes a base that is coupled to a vehicle surface. The base holds the proximity sensor between a lens and a printed circuit board (PCB). The proximity sensor is coupled to the PCB and generates an activation field disposed adjacent to the lens. The housing assembly includes a conductive portion adjacent to the activation field. The conductive portion is grounded.

[0018] Embodiments of the second aspect of the present invention may include any one or combination of the following features:

[0019] ·The surface resistivity of the base is higher than that of the conductive portion; and / or

[0020] ·The conductive portion includes chromium plating.

[0021] According to another aspect of the present invention, a method of manufacturing a vehicle trim assembly includes the steps of forming a housing assembly from a first substrate and a second substrate, wherein the resistivity of the first substrate is higher than that of the second substrate; and electroplating the second substrate.

[0022] Embodiments of the third aspect of the present invention may include any one or combination of the following features:

[0023] ·Placing a proximity switch assembly with a selectively generated activation field within the housing assembly;

[0024] ·Conductively coupling the second substrate to a printed circuit board ground to prevent the second substrate from disrupting the selectively generated activation field;

[0025] ·The first substrate is a first ABS material, and the second substrate is a second ABS material that contains approximately 0.5% to approximately 2% by volume of multi-walled carbon nanotubes and approximately 4% to approximately 6% by volume of high aspect ratio carbon black and has a surface resistivity of approximately 0.8x10 5 ohm / sq to approximately 1.2x10 5 ohm / sq;

[0026] ·Etching the surface of the second substrate with chromic acid;

[0027] · Rinse the surface;

[0028] · Coat the surface with copper;

[0029] · Coat the copper with nickel;

[0030] · Coat the nickel with chromium;

[0031] · Etch the A - surface of the second substrate with chromic acid;

[0032] · Rinse the A - surface;

[0033] · Coat the A - surface with copper;

[0034] · Coat the copper with nickel;

[0035] · Coat the nickel with chromium; and

[0036] · Use a bi - injection molding process to form a housing assembly from the first substrate and the second substrate.

[0037] After studying the following specification, claims, and drawings, those skilled in the art will understand and appreciate these and other aspects, objects, and features of the invention. BRIEF DESCRIPTION OF THE DRAWINGS

[0038] In the drawings:

[0039] Figure 1 is a perspective view of a passenger compartment of a motor vehicle having an overhead console with a grounded trim ring according to an embodiment;

[0040] Figure 2 is Figure 1 an enlarged view of the overhead console, further showing the grounded trim ring;

[0041] Figure 3 is according to an embodiment located Figure 1 a exploded view of one side of a housing assembly, a proximity switch assembly, and a lamp assembly in the overhead console of;

[0042] Figure 4 is a block diagram showing a controller for controlling a lamp assembly based on a proximity switch according to an embodiment;

[0043] Figure 5 is a perspective view of a housing assembly including a base and a trim ring with a metal layer according to an embodiment;

[0044] Figure 6 is Figure 5 a side view of the housing assembly of;

[0045] Figure 7ASchematic diagram of an improved polymeric material that can be used for a decorative ring according to one embodiment;

[0046] Figure 7B According to one embodiment Figure 7A Schematic diagram of the improved polymeric material after acid etching;

[0047] Figure 7C According to one embodiment Figure 7A and Figure 7B Schematic diagram of the improved polymeric material after electroplating; and

[0048] Figure 8 Flowchart of a method for manufacturing a vehicle trim component according to one embodiment. Detailed Description

[0049] As required, detailed embodiments of the present invention are disclosed herein; however, it should be understood that the disclosed embodiments are merely exemplary illustrations of the present invention, which can be embodied in different and alternative forms. The drawings are not necessarily to scale; some schematic diagrams may be exaggerated or minimized to show a functional overview. Therefore, the specific structural details and functional details disclosed herein should not be construed as limiting, but merely as a representative basis for teaching those skilled in the art to adopt the present invention in different ways.

[0050] Referring Figures 1 to 3 , the vehicle console 10 includes a decorative ring 14 that is sleeved around the periphery of the housing 12. The decorative ring 14 is made of a polymeric material and is conductive and grounded. A proximity switch assembly 16 is held in the housing 12. The proximity switch assembly 16 includes a proximity sensor 20 that is close to a sensing pad (e.g., lens 40) for generating an activation field 22. The sensing pad (e.g., lens 40) is close to the conductive decorative ring 14.

[0051] Referring again Figures 1 to 3 , the interior passenger compartment of a motor vehicle 8 is generally shown to have a console 10 with a decorative decorative ring 14. In the depicted embodiment, the decorative decorative ring 14 is chrome-plated on its exposed surface 30. The decorative decorative ring 14 is part of a housing assembly 11 that includes a housing 12 and the decorative decorative ring 14. According to one embodiment, the console 10 further includes a pair of lamp assemblies 32, each lamp assembly being configured to include a proximity switch 34 and being held in the console 10 through the housing assembly 11. In the depicted embodiment, the housing 12 is a cover plate with holes 38 for receiving the sensing pad (lens 40 in the depicted embodiment) of each lamp assembly 32.

[0052] Referring Figures 1 to 8, it is desirable that the grounded decorative ring 14 does not interfere with the activation field 22 of the proximity switch 34. For example, touching the grounded decorative ring 14 with a finger 28 by a user should not interfere with the activation field 22 and activate the proximity switch 34 to turn on or off the light source 74. According to one embodiment, the base or housing 12 of the housing assembly 11 is made of a first polymeric material, while the decorative ring 14 including the heat melt pins 50 is made of a second polymeric material (modified electroplatable ABS material 155). The properties of the second polymeric material generally include (1) electrical conductivity to ground the plating layers 190, 192, 194, and 196 disposed on the conductive decorative ring 14 to the circuit board 52 through the conductive support 54, and (2) low surface resistivity (electrical), which generally allows the layers 190, 192, 194, 196 to be successfully electroplated onto the decorative ring 14.

[0053] Referring again to Figure 3 , each of a pair of lamp assemblies 32 assembled within the aperture 38 of the housing 12 provides an integral assembly of a lamp and a proximity switch 34 for activating the light source 74 to turn the lamp on and off. Each lamp assembly 32 includes: an outer lens 40 having a light transmissive window 41; a light source 74 disposed behind the outer lens 40 to shine light through the transparent window 41 of the outer lens 40; and a proximity switch 34 having one or more proximity sensors 20 disposed adjacent to or near the perimeter of the transparent window 41 of the outer lens 40. The one or more proximity sensors 20 generate an activation field 22 adjacent to the transparent window 41 of the outer lens 40 to sense the activation of the proximity switch 34 for controlling the activation of the light source 74. An inner lens 89 is disposed adjacent to the light source 74. In the illustrated embodiment, the proximity switch 34 is integrally assembled as part of the lamp assembly 32, where the central portion of the outer lens 40 (including the transparent window 41) serves as a touch or sensing pad. A user can contact or be in close proximity to the sensing pad (outer lens 40) to be detected by the activation field 22. However, it should be understood that the proximity switch 34 can be separately assembled from the lamp assembly 32 and employ its own sensing pad and can control any one of a plurality of devices or functions.

[0054] According to one embodiment, each proximity switch 34 disposed in each lamp assembly 32 is shown and described herein as a capacitive switch. Each proximity switch 34 includes a proximity sensor 20 that provides a sensing activation field 22 to sense contact with or the immediate proximity of an object (such as a user's finger 28) closely associated with the proximity sensor 20, such as by a tapping or sliding action made by the user's finger 28. Thus, the sensing activation field 22 generated by the proximity sensor 20 of each proximity switch 34 is a capacitive field in the exemplary embodiment, and the user's finger 28 has conductivity and permittivity, which results in a change or interference occurring in the sensing activation field 22 that is detected in the signal generated from the activation field 22.

[0055] According to one embodiment, the conductive support 54 may be formed of a conductive metal material. Metal may be electroplated on the conductive support 54. The metal conductive support 54 is coupled to a pair of electrodes within the sensor 20 that generate the activation field 22. The activation field 22 generated by the proximity sensor 20 extends beneath the transparent window 41 of the outer lens 40 so that an object such as a user's finger 28, hand, or other body part can enter the activation field 22 at the sensing pad (lens 40) to turn on and off the light source 74. When an object such as a finger 28 sufficiently engages the activation field 22 beneath the sensing pad (e.g., the outer lens 40), an interference in the activation field 22 is detected, causing activation of the proximity switch 34 to turn on the light source 74 or turn off the light source 74.

[0056] The sensor 20 is connected to a first electroplating signal line 84 and a second electroplating signal line 86. The first electroplating signal line 84 and the second electroplating signal line 86 are electrically connected to circuitry in the circuit board 52. In the depicted embodiment, the first electroplating signal line 84 and the second electroplating signal line 86 are respectively depicted as chrome plating towers 56 and 58, which are connected to the circuit board 52 through conductive rubber interfaces 88, 90. In one embodiment, the conductive rubber interfaces 88, 90 are composed of silicone rubber 96 and gold-plated metal wires 97 embedded in the silicone rubber 96. The gold-plated metal wires 97 are generally arranged vertically within the silicone rubber 96 on the circuit board 52 between the ground connection portion of the connector 100 and the bathtub-shaped notches 98 at the tops of each of the towers 56 and 58. The gold-plated metal wires 97 protrude from the top surface 104 of the silicone rubber 96 to be electrically connected to the connector 100, while the gold-plated metal wires 97 protrude from the bottom surface 106 of the silicone rubber to be electrically connected to the chrome-plated bathtub-shaped notches 98 in the chrome plating towers 56 and 58. In the depicted embodiment, the gold-plated metal wires 97 generally contact the bottom surface 99 of the bathtub-shaped notches 98. Thus, the gold-plated metal wires 97 electrically connect the connector 100 to the chrome plating towers 56 and 58. A pulsed drive input signal (e.g., voltage) is applied to one of the signal lines 84 and 86, and an output voltage proportional to the capacitance is received on the other of the signal lines 84 and 86. The output signal and the input signal can be processed by a control circuit (such as a controller) to determine whether an object such as the user's finger 28 sufficiently interacts with the activation field 22 to activate the proximity switch 34.

[0057] According to one embodiment, the conductive material forming the sensor 20 and the first and second electroplated signal lines 84 and 86 can be formed of chromium electroplated onto a thermoplastic polymer such as polycarbonate (PC) or acrylonitrile butadiene styrene (ABS) material. The sensor 20 and the electroplated signal lines 84 and 86 can all be formed on the conductive support 54 in a single electroplating process. According to one embodiment, the process can include a vacuum metallization process. The electroplated signal lines 84 and 86 can be formed to extend from contact with the first and second electrodes of the sensor 20, through the electroplated holes 92 and 94, through the legs or towers 56 and 58 of the conductive support 54, and into contact with the respective conductive rubber interfaces 88, 90 and the connectors 100 on the circuit board 52. Thus, conductive signal lines are formed that connect each of the electrodes of the sensor 20 to one of the towers 56 and 58. The towers 56 and 58 are in turn electrically connected to the circuit board 52 through the conductive rubber interfaces 88, 90 and to the connectors 100. Thus, the control circuit on the circuit board 52 can provide an electrical signal to one of the electrodes and can receive and process a signal from the other of the electrodes to determine activation of the switch. In the depicted embodiment, chromium plating forms a conductive signal path that extends from each of the electrodes, through the conductive rubber interfaces 88, 90 and to the circuit board 52. The polymer material below is a dielectric and is electrically insulating. It should be understood that other shapes and sizes and techniques can be employed to provide a signal path from the electrodes of the sensor 20 to the control circuit on the circuit board 52.

[0058] According to one embodiment, proximity switch 34 can include a control circuit as Figure 4 shown. The controller 110 includes a microprocessor 112 and a memory 114. The controller 110 can execute one or more control routines 116 via the processor 112, as is known in the art, to process capacitor sensor inputs from the capacitive sensors 120 and to control the respective devices shown as lights 1 and 2, each labeled 122. The controller 110 can process the capacitance signals sensed by each of the sensors 120 and compare the sensor values to a threshold to determine activation of the respective switch 34, which indicates activation of one or more control devices such as one of the lights or light sources 74.

[0059] Refer to Figure 3 、 Figure 5 and Figure 6, shows the housing assembly 11. The housing assembly 11 includes a base portion (housing 12) and a conductive decorative ring portion (conductive decorative ring 14). The conductive decorative ring portion includes a hot melt pin 50. A hole 38 is provided in the housing 12 for receiving a proximity switch sensing pad, such as an external lens 40. The housing assembly 11 can be formed by double-shot molding of a first substrate for the housing 12 and a second substrate for the conductive decorative ring 14. In the depicted embodiment, the conductive decorative ring 14 includes an electroplated metal layer 15. According to one embodiment, the metal layer 15 includes a copper layer 190, a semi-bright nickel layer 192, a bright nickel layer 194, and a chromium layer 196.

[0060] Now refer to Figures 5 to 7C , in one embodiment, the housing 12 is made of a non-platable ABS resin, while the decorative ring 14 is made of a platable ABS resin. A typical platable ABS resin has a surface resistivity greater than 1 x 10 15 ohm / sq, making it a very good insulator for dissipating charges that generate capacitive interference. In the depicted embodiment, the conductive decorative ring 14 is made of a modified platable ABS material 155 that has a surface resistivity of approximately 0.8 x 10 5 ohm / sq to approximately 1.2 x 10 5 ohm / sq and is composed of approximately 0.5% to approximately 2% multi-walled carbon nanotubes and approximately 4% to approximately 6% by volume of high aspect ratio carbon black. In various embodiments, the surface resistivity of the modified platable ABS material 155 can be less than 1 x 10 6 ohms / sq. The modified platable ABS material 155 with a surface resistivity less than 1 x 10 6 ohms / sq is more conductive than a typical platable ABS resin with a surface resistivity greater than 1 x 10 15 ohms / sq. The conductivity of the modified platable ABS material 155 that includes the decorative ring 14 (including the hot melt pin 50) allows the metal layer 15 electroplated on the decorative ring 14 to ground the decorative ring 14 to the circuit board 52 through the support 54.

[0061] Now refer to Figures 7A to 7C, The schematic diagram shows an improved electroplatable ABS material 155 and the process of electroplating the improved electroplatable ABS material 155. Generally, in order to impart conductivity to a non-conductive thermoplastic polymer resin, carbon nanotubes and carbon black can be added to the thermoplastic polymer resin. A resin composition including carbon nanotubes and carbon black can be molded. Generally, the surface resistivity of a resin having carbon nanotubes and carbon black molded therein is usually lower than that of a resin without carbon nanotubes and carbon black molded therein. The lower surface resistivity improves the electroplating efficiency. In one embodiment, the improved electroplatable ABS material 155 is an ABS resin having approximately 1% by volume of multi-walled carbon nanotubes and approximately 5% by volume of high aspect ratio carbon black, and a surface resistivity of about 1x10 5 ohm / sq.

[0062] Figure 7A is a schematic diagram of the improved electroplatable ABS material (labeled with identifier 155) before the start of the electroplating process. The improved electroplatable ABS material 155 includes an ABS resin 160 having acrylonitrile (A) 162, butadiene (B) 164, and styrene (S) 166, carbon black 168, and multi-walled carbon nanotubes 170. Refer to Figure 7B , which shows the improved electroplatable ABS material 155 after chromic acid is applied to Figure 7A the surface 172 of the improved electroplatable ABS material 155 shown in. As Figure 7B shown in, chromic acid has removed the butadiene (B) 164 phase from the ABS resin 160 near the etched surface 174 to form voids 176 in which there is no carbon black 168 and multi-walled carbon nanotubes 170. When the carbon black 168 and multi-walled carbon nanotubes 170 are located in the ABS resin 160, they allow chromic acid to remove the butadiene (B) 164 to form voids 176. There is a sufficient amount of multi-walled carbon nanotubes 170 to prevent the carbon black 168 from reaching the surface 172 of the ABS resin 160 and prevent the butadiene (B) 164 from leaving the ABS resin 160. Refer to Figure 7C , after Figure 7B a copper layer 190 is applied above the etched surface 174 of the ABS resin 160 in. The copper layer 190 fills the voids 176 in the etched surface 174. A bond 180 is formed between the copper layer 190 and the ABS resin 160. The number and location of the bond 180 between the copper layer 190 and the ABS resin 160 generally contribute to the chromium layer 196 at the decorative ring surface 30 having a substantially smooth and substantially defect-free appearance. Referring again to Figure 7C , a semi-bright nickel layer 192 is applied above the copper layer 190, a bright nickel layer 194 is applied above the semi-bright nickel layer 192, and a chromium layer 196 is applied above the bright nickel layer 194.

[0063] Carbon nanotubes are allotropes of carbon with a cylindrical nanostructure. The cylindrical carbon nanotubes contain cylindrical carbon molecules with unusual properties, which are valuable for developing materials with extraordinary electrical conductivity. Multi-walled carbon nanotubes consist of more than one graphene wall rolled into a tube. Carbon nanotubes have a three-dimensional tubular molecular structure. Depending on the exact molecular nanotube, carbon nanotubes can be highly conductive or semi-conductive along the tubular axis. Published papers show that nanotubes can carry a current density of 4x 10 9 A / cm 2 , which is more than 1,000 times greater than the current density of metals such as copper. However, due to the nano-scale cross-section of carbon nanotubes, electrons generally only propagate along the axis of the tube. Carbon nanotubes are usually one-dimensional conductors.

[0064] In various embodiments, the decorative ring 14 can be electroplated only on its A-grade surface (the surface visible to passengers when the decorative ring 14 has been installed in the console 10 as part of the housing assembly 11).

[0065] Figure 8 A flowchart of a method 260 for manufacturing a vehicle decorative assembly (e.g., the housing assembly 11) of the depicted embodiment is depicted. The method 260 includes step 262, which provides a housing assembly formed from a first substrate and a second substrate (modified electroplatable ABS material 155), wherein the resistivity of the first substrate is higher than that of the second substrate. Step 264 provides electroplating the second substrate, step 266 provides placing a proximity switch assembly with a selectively generated activation field within the housing assembly, and step 268 provides conductively coupling the second substrate to a printed circuit board ground to prevent the second substrate from disrupting the selectively generated activation field.

[0066] In various embodiments of the method for manufacturing a vehicle decorative assembly, the first substrate (the housing 12) is a non-electroplatable ABS resin, while the second substrate (the decorative ring 14 including the hot melt pins 50) is a modified electroplatable ABS material 155. Referring to Figures 7A to 7C , in various embodiments, electroplating the decorative ring 14 of the second substrate includes etching the surface 172 of the conductive decorative ring 14 with chromic acid, rinsing the etched surface 174, electroplating the etched surface 174 with a copper layer 190, electroplating the copper layer 190 with a semi-bright nickel layer 192, electroplating the semi-bright nickel layer 192 with a bright nickel layer 194, and electroplating the bright nickel layer 194 with a chromium layer 196.

[0067] Processing temperature, molding temperature, and injection speed are important for producing parts with good plating. During the molding process, a relatively hot melt temperature of approximately 245 to 270 degrees Celsius is typically required to reduce internal molding stress. Conversely, a relatively cold molding temperature of approximately 65 to 80 degrees Celsius will typically result in a thick skin on the plastic, with too little butadiene on the surface of the part. Too high a molding temperature will cause more carbon black to reach the top surface, thus reducing the amount of etching. Injection speed is also important. Too fast an injection speed will tend to exhibit an irregular surface pattern visible after chrome plating. Irregular types of surface patterns are commonly referred to as "gate blush" and "jetting marks". Other defects that can be caused by too fast an injection speed are "material streaks" and "burning". All four of these types of defects will greatly affect part quality and will have an impact on yield. One way to minimize these types of defects while still being able to achieve a fully filled part is to reduce the injection speed as much as possible.

[0068] Typically, when the housing assembly 11 is made by a two-shot molding process, it is desirable for both the housing 12 and the decorative ring 14 to be ABS resin so that the housing 12 and the decorative ring 14 have compatible molding parameters.

[0069] Referring again to Figure 3 , a visually appealing chrome surface 30 is provided on the decorative ring 14 by electroplating a metal layer 15 onto the A-surface of the decorative ring 14. The decorative ring 14 includes a hot melt pin 50. The improved electroplatable ABS material 155 for manufacturing the decorative ring 14 allows the hot melt pin 50 to ground the metal layer 15 to the circuit board 52 through the conductive support 54. In the depicted embodiment, the conductive support 54 includes four flanges 55. Each flange 55 has a hole 51 for receiving the hot melt pin 50 of the decorative ring 14. The hot melt pin 50 is inserted through a channel 53 in the housing 12. Thereafter, the hot melt pin 50 is inserted into the hole 51 in the conductive support 54. The hot melt pin 50 is heat melted to the conductive support 54. The conductive support 54 is electrically connected to the circuit board 52 through towers 56 and 58 and through conductive rubber interfaces 88, 90 on towers 56 and 58 at the connector 100. The metal layer 15 of the decorative ring 14 is grounded to a ground connection on the circuit board 52. In various embodiments, the hot melt pin 50 can also be plated.

[0070] Various advantages can be obtained by using the present disclosure. The disclosed electroplatable ABS resin (modified electroplatable ABS material 155) is economical, has a low surface resistivity for electroplating, is conductive to ground to the circuit board 52 through the support member 54, and has a sufficient melting point for hot melting to the conductive support member 54. A unique formulation of a very low percentage of expensive multi-walled carbon nanotubes with low-cost carbon black has been formed in the modified electroplatable ABS material 155 to achieve low surface resistivity and conductivity. Additionally, a bi-injection molding process can be used to minimize the use of the expensive modified electroplatable ABS material 155 within the housing assembly 11.

[0071] Although the lamp assembly 32 with the proximity switch 34, as well as the conductive trim ring 14 and the housing 12, are shown as being located in the overhead console 10, it should be understood that, depending on various vehicle applications, the lamp assembly 32 and the proximity switch 34 with the conductive trim ring 14 in the housing 12 can be located at other positions on the vehicle 8, such as in the instrument panel, on other consoles such as the center console, integrated into a touch screen display for a radio or infotainment system such as for navigation and / or audio display, or at other positions on the vehicle 8.

[0072] The proximity switch can be configured to control other devices. For example, the proximity switch can control any one of a plurality of vehicle devices and functions, such as controlling the movement of a sunroof, controlling the movement of a sunroof shade, controlling the activation of one or more lighting devices, and controlling various other devices and functions.

[0073] In various embodiments, the chromium layer 196 can be another material, such as copper, nickel, black chromium, brass, or gold. Additionally, topcoats such as bright, matte, and brushed can be applied to the surface 30 of the trim ring 14.

[0074] In various embodiments, the housing 12 and the trim ring 14 can be manufactured separately and press-fitted or otherwise connected to manufacture the housing assembly 11. For example, the trim ring 14 can be made of the modified electroplatable ABS material 155, while the housing can be made of another polymeric material such as ABS, polypropylene, polystyrene, or polyvinyl chloride.

[0075] In various embodiments, an electroplated metal can be used for the trim ring 14. The electroplated metal trim ring 14 can be inserted into the housing 12, and the electroplated metal trim ring 14 can be grounded to the circuit board 52.

[0076] It should be understood that changes and modifications can be made to the foregoing structures without departing from the concepts of the present invention, and it should also be understood that these concepts are intended to be covered by these claims unless the appended claims state otherwise in their language.

[0077] According to the present invention, there is provided a vehicle console having: a decorative ring sleeved around the periphery of a housing, wherein the decorative ring comprises a polymeric material and is electrically conductive and grounded; a proximity switch assembly held in the housing, the proximity switch assembly comprising: a proximity sensor close to a sensing pad for generating an activation field, wherein the sensing pad is close to the decorative ring.

[0078] According to an embodiment, the invention above is further characterized by a lamp, wherein the proximity switch assembly is disposed on the lamp, wherein the housing comprises a perforated cover plate, and wherein the sensing pad comprises a lens disposed in the hole.

[0079] According to an embodiment, the proximity sensor is a capacitive sensor.

[0080] According to an embodiment, the decorative ring surrounds the sensing pad.

[0081] According to an embodiment, the decorative ring is electrically connected to a conductive support, and wherein the conductive support is electrically connected to a PCB.

[0082] According to an embodiment, the decorative ring comprises a heat fusion pin connected to the conductive support.

[0083] According to an embodiment, the housing is a first polymeric material, while the decorative ring is a second polymeric material.

[0084] According to an embodiment, the second polymeric material is acrylonitrile butadiene styrene (ABS) comprising about 0.5% to about 2% by volume of multi-walled carbon nanotubes and about 4% to about 6% by volume of high aspect ratio carbon black.

[0085] According to one embodiment, the invention above is further characterized in that the surface resistivity of the acrylonitrile butadiene styrene (ABS) comprising about 0.5% to about 2% by volume of multi-walled carbon nanotubes and about 4% to about 6% by volume of high aspect ratio carbon black is about 0.8x10 5 ohm / sq to about 1.2x10 5 ohm / sq.

[0086] According to an embodiment, the housing and the decorative ring are made during a bi-injection molding process.

[0087] According to the present invention, there is provided a housing assembly for a proximity sensor, the housing assembly having: a base coupled to a vehicle surface, wherein the base holds the proximity sensor between a lens and a PCB, and the proximity sensor is coupled to the PCB and generates an activation field disposed close to the lens; and a conductive portion close to the activation field, wherein the conductive portion is grounded.

[0088] According to an embodiment, the surface resistivity of the base is higher than that of the conductive portion.

[0089] According to an embodiment, the conductive portion includes chromium plating.

[0090] According to the present invention, a method of manufacturing a vehicle trim component is provided, the method having the following steps: forming a housing assembly from a first substrate and a second substrate, wherein the resistivity of the first substrate is higher than that of the second substrate; and electroplating the second substrate.

[0091] According to an embodiment, the above invention is further characterized by the following step: placing a proximity switch assembly having a selectively generated activation field within the housing assembly.

[0092] According to an embodiment, the above invention is further characterized by the following step: electrically connecting the second substrate to a printed circuit board ground to prevent the second substrate from disrupting the selectively generated activation field.

[0093] According to an embodiment, the first substrate is a first ABS material, and the second substrate is a second ABS material, the second ABS material including from about 0.5% to about 2% by volume of multi-walled carbon nanotubes and from about 4% to about 6% by volume of high aspect ratio carbon black and having a surface resistivity of about 0.8x10 5 ohm / sq to about 1.2x10 5 ohm / sq.

[0094] According to an embodiment, the step of electroplating the second substrate further includes: etching the surface of the second substrate with chromic acid; rinsing the surface; coating the surface with copper; coating the copper with nickel; and coating the nickel with chromium.

[0095] According to an embodiment, the above invention is further characterized in that the step of electroplating the second substrate further includes: etching the A-grade surface of the second substrate with chromic acid; rinsing the A-grade surface; coating the A-grade surface with copper; coating the copper with nickel; and coating the nickel with chromium.

[0096] According to an embodiment, the above invention is further characterized in that forming the housing assembly from the first substrate and the second substrate further includes the following step: using a two-shot molding process to form the housing assembly from the first substrate and the second substrate.

Claims

1. A vehicle console, comprising: A decorative ring sleeved on the periphery of the housing, wherein the decorative ring comprises a polymer material and is conductive and grounded; and A proximity switch assembly held in the housing, the proximity switch assembly comprising: A proximity sensor close to a sensing pad for generating an activation field, wherein the sensing pad is close to the decorative ring.

2. The vehicle console according to claim 1, further comprising: A lamp, wherein the proximity switch assembly is disposed on the lamp, wherein the housing comprises a perforated cover plate, and wherein the sensing pad comprises a lens disposed in the hole.

3. The vehicle console according to claim 1, wherein the proximity sensor is a capacitive sensor.

4. The vehicle console according to claim 1, wherein the decorative ring surrounds the sensing pad.

5. The vehicle console according to claim 1, wherein the decorative ring is electrically connected to a conductive support, and wherein the conductive support is electrically connected to a PCB.

6. The vehicle console according to claim 5, wherein the decorative ring comprises a hot melt pin connected to the conductive support.

7. The vehicle console according to claim 6, wherein the housing is a first polymer material and the decorative ring is a second polymer material.

8. The vehicle console according to claim 7, wherein the second polymer material is acrylonitrile butadiene styrene (ABS) comprising 0.5% to 2% by volume of multi-walled carbon nanotubes and 4% to 6% by volume of high aspect ratio carbon black.

9. The vehicle console according to claim 8, wherein the surface resistivity of the acrylonitrile butadiene styrene (ABS) containing 0.5% to 2% by volume of multi-walled carbon nanotubes and 4% to 6% by volume of high aspect ratio carbon black is 0.8 x 10 5 ohm / sq to 1.2 x 10 5 ohm / sq.

10. The vehicle console according to claim 1, wherein the housing and the decorative ring are made during a bi-injection molding process.

11. A vehicle comprising the vehicle console according to any one of claims 1 to 10.

12. A method of manufacturing the vehicle console according to claim 1, the method comprising the steps of: Forming the housing from a substrate; Forming the decorative ring from the polymer material, wherein the resistivity of the substrate is higher than that of the polymer material; and Electroplating the polymer material.

13. The method according to claim 12, further comprising the step of: Placing the proximity switch assembly in the housing.

14. The method according to claim 13, further comprising the step of: Electrically connecting the polymer material to a printed circuit board to prevent the polymer material from disrupting the activation field.

15. The method according to claim 12, wherein the steps of forming the housing from the substrate and forming the decorative ring from the polymer material further comprise the step of: Using a bi-injection molding process to form the housing from the substrate and form the decorative ring from the polymer material.

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