Vehicle interior panel with shape-changing surface

Abstract

A vehicle interior panel includes an electromagnet configured to add a local recess to a base profile of the panel when activated. The recess may provide visual and tactile features along an outer surface of the panel to allow a user to interact with the panel. The panel may be touch-sensitive and / or include a proximity sensor that triggers formation of the recess.

Description

Technical Field

[0001] The present disclosure relates generally to vehicle interior panels, and more particularly to such panels having surfaces that vary in shape. Background Art

[0002] Vehicle interior panels often include switches, buttons, dials, or similar elements for use by vehicle occupants to interact with one or more vehicle systems, such as the audio system, HVAC system, storage compartments, etc. This often frustrates automotive interior designers, who sometimes prefer not to incorporate such practical features as part of the aesthetics of the vehicle interior.

[0003] Co-owned U.S. Patent No. 7,651,145 to Prokop et al. addresses this problem by utilizing a mechanical switch concealed beneath the panel surface. A user can depress the mechanical switch by pressing an overlying layer of material. The disclosed switch activates a relay to operate a storage compartment lock, which can be located remotely from the switch—i.e., so the driver can open the glove box without leaning toward the passenger side of the vehicle. The only indication of the hidden switch's location is a marking on the panel surface that wears off easily and cannot be seen or felt in the dark. Summary of the Invention

[0004] One embodiment of a vehicle interior panel includes an exterior surface having a base profile, and the panel is configured to add a localized recess to the base profile when an electromagnet beneath the exterior surface is activated.

[0005] Another embodiment of the vehicle interior panel includes the features of the previously listed embodiments, wherein the panel includes the electromagnet and further includes: a substrate supporting the electromagnet, a decorative layer disposed on the substrate and providing the outer surface, and an elastic layer between the substrate and the decorative layer, wherein the elastic layer biases the local recess toward the base contour.

[0006] Another embodiment of the vehicle interior panel includes the features of the previously listed embodiments and further includes an actuation pad attached to the inner surface of the trim layer, the actuation pad being attracted to the electromagnet when the electromagnet is activated.

[0007] Another embodiment of the vehicle interior panel includes the features of either of the two previously listed embodiments, and the elastic layer is a spacer fabric.

[0008] Another embodiment of the vehicle interior panel includes the features of any of the three previously listed embodiments, and the elastic layer has a compression set of less than 10%.

[0009] Another embodiment of the vehicle interior panel includes the features of any of the previously listed embodiments and further includes a conductive layer configured as a touch sensor to detect a user touching the local recess, a signal from the touch sensor being received by a controller to control aspects of the vehicle system.

[0010] Another embodiment of the vehicle interior panel includes the features of any of the previously listed embodiments, and the panel is configured to add local recesses to the base profile when the electromagnet is activated with a first polarity, and is configured to add local protrusions to the base profile when the electromagnet is activated with an opposite second polarity.

[0011] Another embodiment of the vehicle interior panel includes the features of any of the previously listed embodiments, and the electromagnet is activated in response to the sensor detecting the presence of a user at the panel.

[0012] Another embodiment of the vehicle interior panel includes the features of any of the previously listed embodiments and further includes a light source beneath the exterior surface that illuminates through the exterior surface when the electromagnet is activated.

[0013] Another embodiment of the vehicle interior panel includes the features of any of the previously listed embodiments, wherein the panel includes an electromagnet and further includes: a decorative layer providing the exterior surface, and an actuation pad attached to an interior surface of the decorative layer, the actuation pad being attracted to the electromagnet when the electromagnet is energized, wherein light from the light source shines through an opening in the pad and through a translucent portion of the decorative layer.

[0014] Another embodiment of the vehicle interior panel includes the features of any of the previously listed embodiments, and the boundaries of the recess are circular and have a diameter in the range of 5 mm to 15 mm.

[0015] Another embodiment of the vehicle interior panel includes the features of any of the previously listed embodiments, and the recess has a depth in the range of 0.1 mm to 2 mm.

[0016] Another embodiment of the vehicle interior panel includes the features of any of the previously listed embodiments, and the recess is configured to detect a touch by a user.

[0017] It is contemplated that any number of the individual features of the above-described embodiments and any other embodiments depicted in the following drawings or description can be combined in any combination to define the invention, except where the features are incompatible. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] Example embodiments will now be described with reference to the following drawings, wherein like numerals represent like elements, and wherein:

[0019] Figure 1 is a cross-sectional view of one embodiment of a vehicle interior panel having a base profile;

[0020] Figure 2 for Figure 1 a cross-sectional view of a base profile wherein the electromagnet adds a localized recess to the base profile; and

[0021] Figure 3 for Figure 1 A cross-sectional view of a device in which an electromagnet adds a local protrusion to the base profile. DETAILED DESCRIPTION

[0022] Described below is a vehicle interior panel that can change its outer surface profile to include local recesses or local protrusions. The outer surface can appear to be the outer surface of an ordinary panel without obvious switches, buttons or other control interfaces, wherein local features appear under predetermined conditions to reveal that the panel surface is actually a control surface for a human-machine interface. To the user, operable buttons connected to one or more vehicle systems or components appear to appear anywhere, providing a modern or futuristic effect, while also providing a smooth, uninterrupted vehicle interior surface when buttons are not needed. Adding local recesses or protrusions to the base profile of the panel can provide visual and tactile features along the surface of the panel to more easily allow the user to interact with the panel.

[0023] Figure 1 is a cross-sectional view of a portion of such a panel 10 having an outer surface 12 having a base profile and Figure 2 The same vehicle interior panel 10 is illustrated with a localized recess 14 added to a base profile. The base profile is the equilibrium profile or rest profile of the exterior surface 12. In this example, the base profile is flat, but it can be any substantially smooth, continuous surface. Figure 2 As shown, when the concave portion 14 is added to the base profile, the outer surface 12 is no longer in its equilibrium profile. Figure 1 and Figure 2 In the embodiment of the present invention, the portion of the outer surface 12 outside the boundary 16 of the recess 14 is in its equilibrium profile, but the portion of the outer surface within the boundary of the recess is not in its equilibrium profile. Alternatively, the base profile can be referred to as the first profile, and the different second profile includes the local recess 14.

[0024] The illustrated panel 10 is a control panel that allows a user to interact with the panel to operate or control one or more systems 18 of the vehicle in which the panel is mounted. The boundary 16 of the recess 14 may define a control area that is visible when the outer surface 12 is in a position such as Figure 1The control area is not visible to the user when its base profile is shown. The panel 10 includes a substrate 20, a decorative cover 22 disposed on the substrate, and an actuator 24 extending between the substrate and the cover 22. The substrate 20 can be formed from injection molded plastic or other suitable rigid material. The decorative cover 22 includes a decorative skin 26 that provides the outer surface 12 of the panel and an elastic layer 28 between the substrate 20 and the skin. The skin 26 can be a thin (e.g., 0.5 mm to 1.0 mm) polymer-based material (e.g., TPO or TPE) or any other sufficiently elastic material that provides the desired aesthetic look and feel to the panel 10. The elastic layer 28 can be a 3D spacer fabric or an elastic foam layer and can be 1.5 mm to 10 mm thick, or 3 mm to 8 mm thick.

[0025] 3D spacer fabrics consist of a pair of thin, spaced-apart surface layers interconnected by a spacer or mesh layer of pile yarns extending therebetween. The spacer layer can be woven from polymeric yarns (e.g., polyester) with diameters ranging from 0.1 mm to 0.3 mm. The spacer fabric can be engineered to provide a desired elastic profile via the material type, size, and tilt angle of the pile yarns. A suitable 3D spacer fabric has a compression set of less than 10%, and preferably less than 5%. Compression set is determined based on ASTM D3574-17 and is expressed as:

[0026]

[0027] Among them C t is the compression set, t o is the original thickness of the test specimen, and t f is the final thickness of the test sample after being subjected to the test conditions. The test conditions consist of compressing the test sample to 50% of its initial thickness between parallel plates at 60°C for 10 seconds, and then removing the compressive force and allowing the test sample to rest without load. After resting without load for 60 seconds, the final thickness t is measured. f .

[0028] The actuator 24 in this example is an electromagnet that generates a polarized magnetic field only when energized. When de-energized, the electromagnet 24 generates no magnetic field. The actuator 24 is in a fixed position relative to the base plate 20. In the illustrated example, the axis of the electromagnet 24 is perpendicular to the outer surface 12 of the panel and is housed within an opening in the base plate 20. Other arrangements are possible.

[0029] Panel 10 also includes an actuation pad 30 attached to the inner surface of skin 26. Actuation pad 30 is made of a material that is attracted and / or repelled by electromagnet 24 when the electromagnet is energized. Actuation pad 30 can be, for example, a magnet or ferromagnetic material attached to the skin via an adhesive or other suitable means. In some embodiments, actuation pad 30 is formed by printing a suitable metal or metallic ink onto the inner surface of skin 26.

[0030] The panel 10 is configured to add localized recesses 14 to the base profile when the electromagnet 24 beneath the outer surface 12 is activated. Specifically, when the electromagnet 24 is activated, the resulting magnetic field attracts the actuation pad 30. In response, the actuation pad 30, along with the localized portion of the surface layer 26, moves toward the electromagnet 24 to form a recessed portion. Figure 2 This movement compresses the localized portion of the resilient layer 28 between the electromagnet 24 and the actuation pad 30, causing the resilient layer to bias the localized resilient layer 28 toward the base contour of the outer surface 12. Thus, when the electromagnet 24 is deactivated, the compressed portion of the resilient layer 28 serves to restore the outer surface 12 to its original position. Figure 1 The base outline in .

[0031] The diameter or width W of the localized recess 14 formed when the electromagnet 28 is activated can be in the range of 5 mm to 15 mm, or preferably in the range of 5 mm to 10 mm. The depth D of the localized recess 14 can be in the range of 0.1 mm to 2.0 mm, or preferably in the range of 0.5 mm to 1.0 mm. The shape of the actuation pad 30 can at least partially define the shape of the boundary 16 of the recess 14. In the illustrated embodiment, the actuation pad 30 is round or circular, so that the boundary 16 of the recess 14 is also round or circular.

[0032] Additional features of the illustrated panel 10 include a sensor 32, a light source 34, and a touch-sensitive layer 36. In some embodiments, the electromagnet 24 is activated in response to the sensor 32 detecting the presence of a user at the panel 10. The sensor 32 can be configured to detect an object (such as a user's hand) when it approaches the outer surface 12 of the panel 10. The illustrated sensor 32 is a proximity sensor and can operate according to any known proximity principle (e.g., ultrasound). The sensor 32 can be configured to actively detect when the outer surface 12 of the panel 10 is at its base profile. The sensor 32 is positioned adjacent to the actuator 24 so that when the user's hand approaches the position below the electromagnet 24 along the outer surface 12, a signal is generated by the sensor. The electromagnet 24 is activated in response to the sensor signal. In the illustrated example, the sensor 32 communicates with a controller 38, which receives the sensor signal and, in response, activates the electromagnet 24 to form the local recess 14. The controller 38 can be configured to ignore the sensor signal when the electromagnet 24 is activated, and / or the controller can be configured to deactivate the electromagnet 24 when the user's hand is no longer detected by the sensor 32. In other embodiments, the controller 38 is omitted, and the sensor 32 simply acts as a switch that activates the electromagnet 24 when the user's hand is detected and deactivates the electromagnet when the hand is not detected.

[0033] The illustrated light source 34 is configured to emit light 40 and illuminate the emitted light through the outer surface 12 of the panel when the electromagnet 24 is activated. The light source 34 may include an LED located at or attached to the end of the electromagnet 24, as shown. In this example, the light source 34 is coaxial with the electromagnet 24 and the actuation pad 30. In this embodiment, the actuation pad 30 is annular with an opening 42 formed therethrough to allow light 40 from the light source 34 to pass through to the decorative surface layer 26. The surface layer 26 may be formed of a translucent and / or colored material, at least at the location of the light source 34, so that the actuation pad 30 and the light source 34 are not visible to the user from the outer surface 12.

[0034] In other examples, the light source 34 is not attached to the electromagnet, but is instead attached to the trim cover 22, such as at one of the opposing surfaces of the elastomeric layer 28, within the elastomeric layer, or along the inner surface of the trim skin 26. For example, the light source 34 may be located within the opening 42 of the actuation pad 30. The light source 34 may share a power source 44 with the electromagnet 24 so that both are activated when the controller 38 connects the power source to one or the other.

[0035] The touch-sensitive layer 36 is configured to detect when a user touches or presses the outer surface 12 of the panel 10 at the localized recess 14. In this example, the touch-sensitive layer 36 is positioned along the inner surface of the decorative skin 26 of the decorative cover 22. The layer 36 can be, for example, a conductive layer that communicates with a controller 38, and the controller can be configured to detect changes in an electrical characteristic of the conductive layer 36. A user pressing on the outer surface 12 can cause a detectable change in the electrical resistance of the layer 36, or the presence of the user's finger can cause a detectable change in the current distribution along the layer 36. Whether a user contacts or presses the outer surface 12 at the localized recess 14 can be determined by known methods, including monitoring the electrical characteristics at a specific location relative to the recess 14. The touch-sensitive layer 36 can be configured according to any known touch-sensitive operating principle.

[0036] Controller 38 can be configured to control aspects of vehicle system 18 when a user's touch is detected at the localized recess 14. In a simple example, the controlled vehicle system 18 is the vehicle ignition system or the vehicle power-on system. When a user enters the vehicle with exterior surface 12 in the base profile, controller 38 initiates a detection routine via sensor 32 to detect the user's hand approaching. Knowing the approximate location of the hidden ignition or power button along panel 10, the user places their hand near the panel near that location. When sensor 32 detects the user's hand approaching panel 10, near the location of the hidden button, controller 38 activates actuator 24 and adds the localized recess 14 to the base profile. When so configured, light source 34 is also activated to emit light and illuminate the recess 14 through exterior surface 12. Controller 38 then initiates a second detection routine to detect when the user presses or touches localized recess 14. Upon detecting this press or touch via touch-sensitive layer 36, controller 38 activates vehicle system 18 to start the vehicle. Once the hidden power button has been exposed and then operated by the user, the controller 38 may deactivate the actuator 24 and / or the light source 34 and wait for some indication that the user is ready to power off the vehicle before again exposing the hidden button.

[0037] This is, of course, only one illustrative use of panel 10, and not all illustrated and described components are required. Continuing with the ignition switch example, when a user enters the vehicle, localized recess 14 can be added to the base profile—that is, controller 38 can receive a signal from some other vehicle component or system, making sensor 32 unnecessary. For example, after the user powers on the vehicle and recess 14 is removed from the base profile, controller 38 can be configured to re-form the recess based on some indication that the vehicle is parked. In another example, touch-sensitive layer 36 is used both to detect a user touching or pressing exterior surface 12 at its base profile and then to detect a user touching or pressing localized recess 14.

[0038] In some embodiments, the actuation pad 30 is magnetically polarized so that when the electromagnet 24 is activated at a first polarity, the localized recess 14 is added to the actuator 30. Figure 2 and when the electromagnet is activated with a second opposite polarity, a local protrusion 14' is added as shown Figure 3 For example, the actuation pad 30 may have a north pole facing the electromagnet 24 and a south pole facing the decorative surface layer 26. When the electromagnet 24 is activated with a first polarity, its south pole faces the actuation pad 30, so that the local recess 14 is formed. When the electromagnet 24 is activated with a second polarity, its north pole faces the actuation pad 30, so that the actuation pad is repelled by the electromagnet 24 and a local protrusion 14' is formed. When the panel 10 is configured to have this function, the actuation pad 30 is attached to the inner surface of the decorative surface layer 26 and is not attached to the elastic layer 28, so that the actuation pad is free to move away from the elastic layer, as shown in FIG. Figure 3 shown.

[0039] Other functions related to the sensor 32, light source 34, touch sensitive layer 36 and controller 38 remain the same as above. Figure 1 and Figure 2 The local protrusion 14 ′ may have the same shape and width W as the local recess 14 at its boundary 16 ′, and the height H of the local protrusion 14 ′ may be the same as or within the same range as the depth of the local recess 14 .

[0040] It should be understood that the above is a description of one or more embodiments of the present invention. The present invention is not limited to the specific embodiments disclosed herein, but is limited only by the following claims. In addition, the statements contained in the foregoing description relate to specific embodiments and should not be interpreted as limitations on the scope of the present invention or on the definitions of terms used in the claims, unless a term or phrase is clearly defined above. Various other embodiments and various changes and modifications to the embodiments disclosed by the present invention will become apparent to those skilled in the art. All such other embodiments, changes and modifications are intended to fall within the scope of the appended claims.

[0041] As used in this specification and claims, the terms "example," "for example," "for instance," "such as," and "similar," and the verbs "comprise," "have," "include," and their other verb forms, when used in conjunction with a list of one or more components or other items, should each be interpreted as open-ended, meaning that the list should not be construed to exclude other additional components or items. Other terms should be interpreted using their broadest reasonable meaning unless they are used in a context that requires a different interpretation.

Claims

1. A vehicle interior panel having an exterior surface with a base contour, wherein the panel is configured to add a localized recess to the base contour when an electromagnet beneath the exterior surface is activated.

2. The vehicle interior panel of claim 1 , wherein the panel includes the electromagnet and further comprises: a base plate supporting the electromagnet; a decorative layer, the decorative layer being disposed on the substrate and providing the outer surface; and An elastic layer is interposed between the substrate and the decorative layer, wherein the elastic layer biases the local recess toward the base contour. 3 . The vehicle interior panel of claim 2 , further comprising an actuation pad attached to an inner surface of the trim layer, the actuation pad being attracted to the electromagnet when the electromagnet is activated. The vehicle interior panel of claim 2 , wherein the elastic layer is a spacer fabric.

5. The vehicle interior panel of claim 2, wherein the elastic layer has a compression set of less than 10%.

6. The vehicle interior panel of claim 2 , further comprising a conductive layer configured as a touch sensor to detect a user touching the localized recess, a signal from the touch sensor being received by a controller to control aspects of a vehicle system.

7. The vehicle interior panel of claim 1 , wherein the panel is configured to add the localized recess to the base profile when the electromagnet is activated with a first polarity, and to add the localized protrusion to the base profile when the electromagnet is activated with an opposite second polarity.

8. The vehicle interior panel of claim 1, wherein the electromagnet is activated in response to a sensor detecting the presence of a user at the panel.

9. The vehicle interior panel of claim 1 further comprising a light source beneath the exterior surface, the light source illuminating through the exterior surface when the electromagnet is activated.

10. The vehicle interior panel of claim 9, wherein the panel includes the electromagnet and further comprises: a decorative layer providing the outer surface, and an actuation pad attached to the inner surface of the decorative layer, the actuation pad being attracted to the electromagnet when the electromagnet is energized, wherein light from the light source shines through an opening in the pad and through a translucent portion of the decorative layer. 11 . The vehicle interior panel according to claim 1 , wherein a boundary of the recess is circular and has a diameter in the range of 5 mm to 15 mm. 12 . The vehicle interior panel according to claim 1 , wherein the recess has a depth in the range of 0.1 mm to 2 mm.

13. The vehicle interior panel of claim 1, wherein the recess is configured to detect a touch by a user.

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