Decorative element and method of manufacturing the same

Abstract

This application provides a decorative element and a method for manufacturing the same. A sensing and lighting element is configured to be positioned directly behind a first surface of an automotive decorative article. The decorative element comprises: a sensing and lighting element; and a concealed front functional thermoplastic polyolefin (TPO) film.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims the benefit of U.S. Provisional Application No. 63 / 054,079, filed on July 20, 2020, and U.S. Patent Application No. 17 / 376685, filed on July 15, 2021, the entire contents of which are incorporated herein by reference. Technical Field

[0003] Exemplary embodiments of the present disclosure relate to sensing and lighting elements that may be used with trim components. Background Art

[0004] To sense through soft surfaces, such as those with substrates, foams, and skin materials, the sensor is typically located behind the substrate and must sense through the complete stack of materials. This can lead to several issues. Due to the fundamental operating mode of capacitive sensors, the sensitivity of this arrangement can be reduced. For the same reason, the signal-to-noise ratio can be low, making it more difficult to interpret operator interactions with the sensing element. These conditions affect the placement distance of the sensor element (and icon).

[0005] Some attempts to position the sensing and lighting elements between the skin material and the substrate have resulted in an operator being able to feel the construction of the part. This is a highly undesirable situation.

[0006] Brief Description

[0007] The present disclosure uniquely solves known problems of other designs.

[0008] The present disclosure attempts to address the shortcomings of these systems by moving the sensing and illumination elements as close as possible to the first surface of the component, thereby removing many layers from the sensing and illumination path. The construction of the disclosed embodiments utilizes inherently soft materials, which, combined with the foam now located behind the elements, provide the ultimate in softness. The sensitivity of the disclosed embodiments is the best and the signal-to-noise ratio is the best for this arrangement. Due to the greatly reduced light path of the present invention, light transmission losses are likely to be minimal, as is color shift. The embodiments disclosed herein proactively address light bleed issues by incorporating light blocking features between icons / symbols.

[0009] While some applications have components that the operator can feel, embodiments of the present disclosure directly address this problem. By using a stretchable sensor design and embedding the components in a slightly stiffer but thinner layer, the operator cannot feel the components.

[0010] A decorative element is disclosed, comprising: a sensing and lighting element; and an outer display surface layer, wherein the sensing and lighting element is directly fixed to the back side of the outer display surface layer.

[0011] In addition to one or more of the features described above, or as an alternative to any of the preceding embodiments, the outer display surface layer is formed of a thermoplastic polyolefin having a plurality of hidden icons that are visible from the outer display side of the outer display surface layer only when they are illuminated by the light source of the sensing and lighting element.

[0012] In addition to one or more features described above, or as an alternative to any of the preceding embodiments, the sensing and lighting element includes a flexible capacitive sensor.

[0013] In addition to one or more features described above, or as an alternative to any of the preceding embodiments, the sensing and lighting element includes a base layer; a light emitting diode (LED) frame; and an upper layer.

[0014] In addition to one or more features described above, or as an alternative to any of the preceding embodiments, the substrate layer includes a plurality of sensor elements, a ground plane, and associated traces, all of which are located on a stretchable membrane.

[0015] Additionally or alternatively to any preceding embodiment, the plurality of sensor elements may be flexible capacitive sensors.

[0016] Additionally or alternatively to any of the preceding embodiments, in addition to one or more features described above, or as an alternative to any of the preceding embodiments, a single color layer is printed on the plurality of sensor elements.

[0017] Additionally or alternatively to any of the preceding embodiments, in addition to one or more of the features described above, or as an alternative to any of the preceding embodiments, a reflective dot pattern is applied to the solid color layer.

[0018] In addition to one or more of the features described above, or as an alternative to any of the preceding embodiments, the light emitting diode (LED) frame includes a flexible frame that carries a plurality of light emitting diodes (LEDs).

[0019] In addition to one or more features described above, or as an alternative to any of the preceding embodiments, the plurality of light emitting diodes (LEDs) are side-emitting LEDs.

[0020] In addition to one or more of the features described above, or as an alternative to any of the preceding embodiments, the upper layer is a molded layer comprising a light guide and a light shading material, each light guide and light shading material being molded onto a component respectively comprising the base layer and the light emitting diode (LED) frame.

[0021] Additionally or alternatively to any of the preceding embodiments, the light guide comprises optically clear silicone and the light blocking material comprises black silicone.

[0022] Additionally or alternatively to any of the preceding embodiments, the optically clear silicone and the black silicone are applied via an overmolding process.

[0023] Additionally or alternatively to any of the preceding embodiments, the optically clear silicone may have a thickness that prevents a user from feeling the plurality of LEDs of the LED frame through the outer display surface layer.

[0024] Additionally or alternatively to any of the preceding embodiments, the sensing and illumination elements are secured directly to the back side of the outer display surface layer with an optically clear adhesive.

[0025] Additionally or alternatively to any of the preceding embodiments, the trim element is an interior trim piece of a vehicle.

[0026] Also disclosed is a method of forming a decorative element, comprising securing a sensing and lighting element to an outer display surface layer, wherein the sensing and lighting element is secured directly to a back side of the outer display surface layer.

[0027] In addition to one or more of the features described above, or as an alternative to any of the preceding embodiments, the outer display surface layer is formed of a thermoplastic polyolefin having a plurality of hidden icons that are visible from the outer display side of the outer display surface layer only when they are illuminated by the light source of the sensing and lighting element.

[0028] In addition to one or more of the features described above, or as an alternative to any of the preceding embodiments, the sensing and lighting element includes: a base layer; a light emitting diode (LED) frame; and an upper layer, and wherein the base layer includes a plurality of sensor elements, a ground plane, and associated traces, all of which are located on a stretchable membrane.

[0029] In addition to one or more of the features described above, or as an alternative to any of the preceding embodiments, the upper layer is a molded layer comprising a light guide and a light shading material, each of the light guide and light shading material being molded onto a component respectively comprising the base layer and the light emitting diode (LED) frame. BRIEF DESCRIPTION OF THE DRAWINGS

[0030] The following description should not be considered limiting in any way. Referring to the accompanying drawings, like elements are numbered likewise:

[0031] Figure 1 is a perspective view of a decorative component having a flexible capacitive sensor according to one non-limiting embodiment of the present disclosure;

[0032] Figure 2 and Figure 3 is an exploded view of a portion of a trim component having a flexible capacitive sensor according to one non-limiting embodiment of the present disclosure;

[0033] Figure 4-6 is a diagram illustrating a sensor element of a decorative component according to one non-limiting embodiment of the present disclosure;

[0034] Figure 7 is a diagram illustrating a light emitting diode (LED) subassembly of a trim component according to one non-limiting embodiment of the present disclosure;

[0035] Figure 8-12 is a diagram illustrating a sensor element and light emitting diode (LED) subassembly of a trim component according to one non-limiting embodiment of the present disclosure;

[0036] Figure 13-15 is a view showing a portion of a decorative component having a flexible capacitive sensor according to one non-limiting embodiment of the present disclosure; and

[0037] Figure 16 is a flow chart illustrating a method of assembling a trim component according to one non-limiting embodiment of the present disclosure. DETAILED DESCRIPTION

[0038] A detailed description of one or more embodiments of the disclosed apparatus and method is presented herein by way of example and not limitation with reference to the accompanying figures.

[0039] Now refer to Figure 1 , shows a perspective view of a trim component or decorative element 10 having a flexible capacitive sensor according to one non-limiting embodiment of the present disclosure. In one non-limiting embodiment, the trim component can be an interior trim piece of a vehicle. Non-limiting examples include an armrest, a center console, an interior trim panel, a portion of an instrument panel, and any other suitable portion of a vehicle.

[0040] Figure 2 and Figure 3FIG2 is an exploded view of a portion 12 of a decorative component or decorative element 10 having a flexible capacitive sensor according to one non-limiting embodiment of the present disclosure. Portion 12 includes a sensing and lighting element 14 secured directly to an outer display surface layer 16. According to one non-limiting embodiment of the present disclosure, outer display surface layer 16 can be formed from a thermoplastic polyolefin (TPO) and include a plurality of hidden icons 18 that are only visible from an outer display surface 20 of outer display surface layer 16 when illuminated by a light source located behind outer display surface layer 16. Alternatively, icons 18 can be visible when not illuminated (e.g., printed with visible indicia that can be illuminated from the back to make them brighter) and further illuminated by the light source so that they are clearly visible at night or when the area surrounding decorative element 10 is dark. In yet another embodiment, outer display surface layer 16 can include both visible icons 18 and hidden icons 18, wherein hidden icons 18 are only visible from outer display surface 20 of outer display surface layer 16 when illuminated by a light source. Visible icons 18 located behind outer display surface layer 16 may be illuminated by a light source located behind outer display surface layer 16 , or alternatively, visible icons 18 are not illuminated by a light source located behind outer display surface layer 16 .

[0041] It should also be understood that materials other than thermoplastic polyolefin (TPO) may be used for outer display surface layer 16 (eg, leather, polyurethane, thermoplastic polyurethane (TPU), or any other suitable material).

[0042] Furthermore, as will be discussed herein, the sensing and lighting element 14 is secured to the back side 21 of the outer display surface layer 16. Thus, the sensing and lighting element 14 is secured directly to the back side 21 of the outer display surface layer 16. In other words, no other components are located between the back side 21 of the outer display surface layer 16 and the sensing and lighting element 14.

[0043] The sensing and lighting element 14 comprises three main components, namely a base layer or sensor element 22, a middle layer or light emitting diode (LED) frame or light emitting diode (LED) subassembly 24 and an upper layer 26, such as Figure 2 and 3 Now at least refer to Figure 2-6 , the base layer or sensor element 22 includes a plurality of sensor elements 28, a ground plane 30, and associated traces 32, all of which are located on a thin stretchable membrane 34. As used herein, the stretchable membrane 34 is intended to cover a portion of the sensor element 28 that is capable of elastic deformation without breaking or degrading. It should also be understood that the stretchable membrane 34 is also flexible. In an exemplary embodiment of the present disclosure, the plurality of sensor elements 28 are capacitive sensor elements.

[0044] The thin stretchable film 34 provides a base or surface for printing conductive ink and other inks on the top surface, and its opposite side (without conductive ink) provides a base or surface for bonding polyurethane (PU) foam thereto. The thin stretchable film 34 also provides thread retention during the subsequent sewing step. The ground plane 30 and associated traces 32 and sensor elements 28 are formed by a stretchable durable conductive ink applied to the thin stretchable film 34. As used herein, stretchable durable conductive ink is intended to cover inks that are capable of elastic deformation without catastrophic degradation (e.g., destroying the conductive path). A dielectric bridge 36 formed by a dielectric ink that allows the signal trace to cross the ground plane 30 is also shown, where applicable depending on the type of sensor element 28 (e.g., a slider sensor element). In addition, a plurality of carbon pads 38 are provided to provide improved electrical connections at the terminal points of the electrical traces 32.

[0045] A single color layer or ink 40 is printed over the sensor elements 28. The single color layer 40 hides the sensor elements 28 from view, improves light management, and protects the printed ink from degradation. In one embodiment, the single color layer 40 may not need to cover all of the silver ink sensor elements 28 if a subsequent overmolding step (as discussed below) provides adequate protection.

[0046] Also shown is a reflective dot pattern 42 applied to the monochromatic layer 40. The reflective dot pattern 42 comprises reflective ink and provides light uniformity in the area of ​​the icons 18. The base layer or sensor element 22 is decorated before the intermediate layer or LED frame or LED subassembly 24 is applied to the base layer or sensor element 22. In addition, the base layer or sensor element 22 can be provided with a plurality of positioning points 44 for the intermediate layer or LED frame or LED subassembly 24.

[0047] Now at least reference Figure 1-8 , the middle layer or LED frame or LED subassembly 24 includes a flexible frame 46 that carries a plurality of light emitting diodes (LEDs) 48 and their associated traces 50. When the associated sensor element 28 is activated, the LEDs 48 illuminate the icon 18. In one non-limiting embodiment, the LEDs 48 are side-emitting or side-emitting single-color LEDs. Of course, any other suitable type of LEDs may be used. The middle layer or LED frame or LED subassembly 24 is bonded to the sensor element 22 on top of the base layer or single-color layer 40 such that the LEDs 4 are positioned to illuminate the area 18 adjacent to the associated sensor element 28 and its associated icon. See at least Figure 8 At this point, the subassembly including the base layer or sensor element 22 and the intermediate layer or LED frame or LED subassembly 24 is ready for overmolding. Alternatively, the intermediate layer or LED frame or LED subassembly 24 can be overmolded and become its own subassembly.

[0048] Referring now to at least 1-10, the upper layer 26 is a molded layer comprising a light guide 52 and a light shielding material 54 that is molded onto an assembly comprising the base layer or sensor element 22 and the intermediate layer or LED frame or LED subassembly 24. The light guide 52 comprises optically clear silicone, while the light shielding material 54 comprises black or opaque silicone. These materials are molded onto the base layer or sensor element 22 and the intermediate layer or LED frame or LED subassembly 24 through a secondary molding process.

[0049] Optically clear silicone, including light guides 52, is molded directly onto the subassembly, including the base layer or sensor element 22 and the middle layer or light-emitting diode (LED) frame or light-emitting diode (LED) subassembly 24, as the first of two silicone molding operations. These light guides 52 transmit light from the LEDs 48 to the icon 18. The light guides 52 also cover the LEDs 48 so that the user cannot feel the LEDs 48 in the final assembly. In other words, the thickness of the light guides 52 is large enough that the user cannot feel the LEDs 48 through the upper layer 26. In other words, the user's fingers will not be able to feel the LEDs 48 through the upper layer 26.

[0050] It is desirable to optically couple the LEDs 48 and the monochromatic ink 40 and reflective ink 42 on the substrate layer or sensor element 22. The optically clear silicone comprising the light guide 52 should have the same or better stretch as the substrate film 34. In one non-limiting embodiment, the Shore "A" durometer of the light guide 52 should be 55 to 60.

[0051] The light-blocking silicone 54 is molded directly onto the subassembly comprising the base layer or sensor element 22 and the intermediate layer or light-emitting diode (LED) frame or LED subassembly 24. The light-blocking silicone 54 is the second of two silicone molding operations. The light-blocking element 54 reduces light leakage from one icon 18 to another. It also fills the surrounding area, providing a level surface for the light guide 52. The hardness and shrinkage level of the light-blocking element 54 should be as close as possible to that of the optically clear silicone 52. In addition, it is desirable for the sensing and lighting elements 14 to have the same final thickness. Therefore, the light guide 52 and the light-blocking silicone 54 should be flush with each other.

[0052] It is assumed that the top layer will be a secondary process, possibly in silicone. This combination of subassemblies can be broken down in different ways. For example, an LED element can be combined with a silicone element as its own subassembly. The materials discussed here are just one possible option. It should also be understood that other transparent materials can be used for the light guide 52. For example, optically transparent polyurethane can be used instead of silicone for the light guide 52. In another embodiment, a pre-cut opaque silicon sheet will provide the light-shielding silicone portion 54, and the sheet will be provided with a cutout portion that defines the light guide 52. The sheet can be applied with an adhesive and adhered to the assembly including the base layer or sensor element 22 and the intermediate layer or light-emitting diode (LED) frame or light-emitting diode (LED) subassembly 24. Thereafter, the light guide 52, including a small piece of silicone configured to fit into the corresponding cutout portion, is inserted therein and encapsulated in place with the silicone material. Alternatively, the optically transparent silicone is molded into the cutout portion of the light-shielding material sheet 54.

[0053] At this point, the top surfaces of the light guide 52 and light-blocking silicone 54 are cleaned and an optically clear primer or treatment 56 is applied. The optically clear primer or treatment 56 ensures proper adhesion of the sensing and illumination elements 14 to the outer display surface layer 16. In alternative embodiments, the primer or treatment 56 may not be necessary based on the final material selection.

[0054] At this point, now at least refer to Figure 1-15 In the embodiment, the sensing and lighting element 14 is now ready to be adhered or laminated to the outer display surface layer 16. Figure 12 , an optically clear adhesive 58 is applied to the top surface of the sensing and lighting element 14. This top surface will be directly secured to the inner surface or backside 21 of the outer display surface layer 16. It should be understood that there are many ways to bond the sensing and lighting element 14 to the outer display surface layer 16. The adhesive 58 must be optically clear, temperature stable, flexible, and have the desired peel strength for the desired application.

[0055] Once the sensing and lighting element 14 is adhered or laminated to the outer display surface layer 16, the outer display surface layer 16 is decorated and the terminals 70 and 72 are crimped to the terminals of the base layer or sensor element 22 and the intermediate layer or light emitting diode (LED) frame or light emitting diode (LED) subassembly 24. At this point, the portion 12 of the decorative component 10 having a flexible capacitive sensor is now provided according to various embodiments of the present disclosure. See at least Figure 14 and 15 .

[0056] Now, portion 12 contains all the functions of the final part and is ready to be sewn to other parts, such as side panels 74 extending from portion 12 of trim part 10. Although Figure 1Only one side panel is shown in FIG. 1 , with at least two side panels 74 and others contemplated to be sewn to portion 12 if desired.

[0057] During this stitching step, the components (e.g., portion 12 and side panels 74) are stitched together to form a subassembly to be wrapped around the foam-covered substrate. After the stitching step, adhesive is applied to the scrim side of the stitched assembly (portion 12 and side panels 74). In one embodiment, it may be necessary to apply adhesive to both components to be joined together (e.g., the foam-covered substrate and portion 12 with side panels 74). In another embodiment, it may not be necessary to apply adhesive to the scrim side of the stitched assembly (portion 12 and side panels 74) if applying adhesive to the foam-substrate subassembly is sufficient.

[0058] The portion 12 and side panels 74 are now bonded to the foam covered substrate using bonding techniques known to those skilled in the relevant art (e.g., air bag lamination). Thereafter, the edges of the part or assembly 10 are manually wrapped and the trim assembly 10 is ready for use.

[0059] Now refer to Figure 16 , a flow chart 100 illustrating a method of assembling a final trim component 10 is shown. In step 102, the portion 12 is sewn to other components, such as the side panels 74 extending from the portion 12 of the trim component 10. Although Figure 1 Only one side panel is shown, at least two side panels 74, and other panels are contemplated for sewing to portion 12, if desired. Thereafter, in step 104, adhesive is applied to the scrim side of the sewn assembly (portion 12 and side panels 74). In one embodiment, it may be necessary to apply adhesive to both components to be joined together (e.g., the foam-covered substrate and portion 12 with side panels 74). See step 106. In yet another embodiment, if applying adhesive to the foam substrate subassembly (step 106) is sufficient, it may not be necessary to apply adhesive to the scrim side of the sewn assembly (portion 12 and side panels 74, step 104). Thereafter, in step 108, portion 12 and side panels 74 are pre-secured to the foam-covered substrate. In step 110, portion 12 and side panels 74 are now bonded to the foam-covered substrate using bonding techniques known to those skilled in the relevant art (e.g., airbag lamination). There and at step 112 , the edges of the part or assembly 10 are manually wrapped and the assembly 10 is trimmed, and at step 114 , the hardware module is snapped into place and the flexible leads of the part or assembly 10 are inserted into the hardware module and the part or assembly 10 is ready for use.

[0060] The terms used herein are for the purpose of describing particular embodiments only and are not intended to limit the present disclosure. As used herein, the singular forms "a," "an," and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms "comprising" and / or "including," when used in this specification, specify the presence of the recited features, integers, steps, operations, elements, and / or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or groups thereof.

[0061] Although the present disclosure has been described with reference to one or more exemplary embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the present disclosure. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the present disclosure without departing from the essential scope of the present disclosure. Therefore, the present disclosure is not limited to the particular embodiments disclosed as the best mode contemplated for carrying out the present disclosure, but rather, the present disclosure will include all embodiments falling within the scope of the claims.

Claims

1. A decorative element comprising: Sensing and lighting components, including flexible capacitive sensors; and an outer display surface layer, wherein the sensing and lighting element is directly secured to a back side of the outer display surface layer, wherein the sensing and lighting element comprises a base layer; an LED frame; and an upper layer; The upper layer is a molded layer including a light guide and a light shielding material, each light guide and light shielding material are molded onto a component respectively, and the component includes the base layer and the light emitting diode frame.

2. The decorative element according to claim 1, wherein The outer display surface layer is formed of a thermoplastic polyolefin having a plurality of hidden icons that are visible from an exterior display face of the outer display surface layer only when the icons are illuminated by the light source of the sensing and illumination element.

3. The decorative element according to claim 1, wherein The base layer includes a plurality of sensor elements, a ground plane, and associated traces, all of which are located on a stretchable membrane.

4. The decorative element according to claim 3, wherein The plurality of sensor elements are flexible capacitive sensors.

5. The decorative element according to claim 3, wherein A single color layer is printed on the plurality of sensor elements. The decorative element according to claim 5 , wherein: A reflective dot pattern is applied to the solid color layer.

7. The decorative element according to claim 1, wherein The light emitting diode frame includes a flexible frame carrying a plurality of light emitting diodes.

8. The decorative element according to claim 7, wherein The plurality of light emitting diodes are all side-emitting light emitting diodes.

9. The decorative element according to claim 1, wherein The light guide comprises optically clear silicone and the light blocking material comprises black silicone.

10. The decorative element according to claim 9, wherein The optically clear silicone and the black silicone are applied by a secondary molding process.

11. The decorative element according to claim 9, wherein The thickness of the optically clear silicone prevents a user from feeling the plurality of LEDs of the LED frame through the outer display surface layer.

12. The decorative element according to claim 1, wherein The sensing and lighting elements are secured directly to the back side of the outer display surface layer with an optically clear adhesive.

13. The decorative element according to claim 1, wherein The decorative element is an interior trim piece of a vehicle.

14. A method of forming a decorative element, comprising: securing a sensing and lighting element to an outer display surface layer, wherein the sensing and lighting element is secured directly to a back side of the outer display surface layer, wherein the sensing and lighting element comprises a base layer; an LED frame; and an upper layer; The upper layer is a molded layer including a light guide and a light shielding material, each light guide and light shielding material are molded onto a component respectively, and the component includes the base layer and the light emitting diode frame.

15. The method according to claim 14, wherein The outer display surface layer is formed of a thermoplastic polyolefin having a plurality of hidden icons that are visible from an exterior display face of the outer display surface layer only when the icons are illuminated by the light source of the sensing and illumination element.

16. The method according to claim 14, wherein The base layer includes a plurality of sensor elements, a ground plane, and associated traces, all of which are located on a stretchable membrane.

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