Soft upper trim panel for a switch assembly of a vehicle door and method for manufacturing this

Abstract

Method for manufacturing a soft upper cover (100) for a switch assembly of a vehicle door, in which a molded layer and a transparent layer are formed in a state in which a light guide plate (300) is attached to an upper substrate (200), the method comprising: (a) Injection molding of the upper substrate (200) such that a recessed groove (230) and a projecting groove (240) interact, wherein a switch module is inserted into the recessed groove (230) in a lower side of the upper substrate (200) and a light guide plate (300) in which a symbol is engraved is inserted into the projecting groove (240) in an upper side of the upper substrate (200); (b) Mounting the light guide plate (300) in the projection groove (240), wherein the light guide plate (300) has a thickness equal to the thickness of the projection groove (240); (c) Foam forming of a foam (400) on the upper substrate (200) around the projection groove (240) in a state in which the upper substrate (200) which is mounted with the light guide plate (300) is inserted, wherein the foam (400) has a thickness equal to the thickness of each of the projection groove (240) and the light guide plate (300); (d) Applying an adhesive (600) to the upper surfaces of the projection groove (240), the light guide plate (300) and the foam (400); and (e) Applying a transparent skin (500) to the upper surfaces of the projection groove (240), the light guide plate (300) and the foam (400) in a vacuum membrane press.

Description

BACKGROUND 1. Technical field

[0001] The present invention relates to a soft upper panel of a vehicle door in which an upper substrate, a foam, and a transparent skin are laminated, and more particularly to a soft upper panel for a switch assembly of a vehicle door in which a switch configured to maintain the continuity of a transparent skin and display lock and unlock symbols on the transparent skin is easily mounted on an upper substrate, and a method of manufacturing the same. 2. Description of the relevant technology

[0002] A foamed skin covering 70 (see Fig. 1) on an upper door panel side is disclosed in the document KR 10 1 087 875 B1.

[0003] This means that a substrate for a vehicle door panel is divided into an injection-molded upper substrate, a middle substrate, and a lower substrate. The three divided substrates are connected by screws or the like.

[0004] In addition, a foam-molded foam 50 and a transparent skin 60 are further laminated on the upper substrate 20 (see Fig. 1).

[0005] The foam 50 provides a cushioning feeling and the transparent skin 60 provides a luxurious feeling, like a leather feel.

[0006] In the document JP 4 218 660 B2, when a driver places a hand near a driver’s seat, as in the Fig. 2 and Fig. 3, operation symbols, on the other hand, are displayed on a decorative plate 14 and the driver presses a desired operation symbol to operate.

[0007] That is, a switch device 10 is configured to display a symbol that is a hidden type of switch embedded in a substrate of a door panel of a vehicle.

[0008] The hidden switch device 10 has a structure embedded only in a hard substrate. Specifically, the hidden switch device 10 is embedded such that it is disposed between an upper portion and a lower portion of a lower panel.

[0009] Therefore, drivers leaving the vehicle may not check a symbol inside the vehicle through a window.

[0010] In particular, after a door has been locked or unlocked when leaving the vehicle, drivers tend to check the symbol through the window, but such a requirement may not be satisfactory.

[0011] Specifically, when the conventional switch device 10 is mounted on an upper panel, holes into which the switch device 10 is inserted should be formed in the transparent skin 60 and the foam 50, and after the switch is mounted, surface treatment should be performed on the transparent skin 60. However, the surface treatment is post-processed and thus may not be attractive and likely to lower a price of the vehicle.

[0012] Due to the possibility of damage to the transparent skin 60, the conventional hidden switch device 10 was embedded in a hard substrate, as shown in the Fig. 2 and Fig. 3 illustrates.

[0013] Meanwhile, in the document KR 10 2017 0 074 740 A, the same problem occurs similar to that shown in the document JP 4 218 660 B2, since a switch is provided with a substrate.

[0014] The document EP 2 085 205 A1 describes a method for producing a toothbrush with a body comprising a handle region, a head region and a neck region located between the handle region and the head region, and with functional components arranged at least partially within the body, which comprise an electrically operated functional unit and an electrical supply device for the functional unit, which comprises an energy store, in which the body is produced from at least one hard component serving as a strength carrier and at least one soft component by injection molding, and at least some of the functional components are at least partially directly overmolded with the plastic forming the soft component during the production of the body.

[0015] Document EP 0 622 585 A1 discloses a switch or knob assembly having a graphic image of a first color that, when backlit, provides a graphic image of a different color. The switch or knob assembly comprises: a transparently molded cap member having a predetermined shape, a first outer surface, and a second inner surface, the second inner surface being provided with opaque means having a predetermined clear portion defining the graphic image; first translucent coloring means on the second side of the cap covering at least the clear portion of the graphic image; second translucent coloring means on the second side of the cap covering at least the first coloring means; and transparent knob support means connected to the cap to support the cap and cooperate with the second side of the cap behind the first and second coloring means.In this arrangement, when viewed from the first side of the cap, the button arrangement comprises a graphic image having a color corresponding to that of the first colorant, and when backlit from the second side of the cap, the graphic image has a different color. SUMMARY1. Technical problem

[0016] The present invention has been made to solve the above-mentioned problems, and a technical object of the present invention is to provide a soft door trim for a switch assembly of a vehicle capable of displaying symbols on a transparent skin on an upper door trim thereof without damaging the transparent skin, and a method of manufacturing the same. 2. Solution to the problem

[0017] In order to achieve the above objects, a method of manufacturing a soft upper panel for a switch assembly of a vehicle door according to claim 1 of the present invention is a method of manufacturing a soft upper panel for a switch assembly of a vehicle door in which a molding layer and a transparent layer are formed in a state where a light guide plate is attached to an upper substrate, the method comprising: (a) injection-molding the upper substrate such that a recessed groove and a projection groove communicate with each other, a switch module is inserted into the recessed groove in a lower side of the upper substrate, and a light guide plate, on which a symbol is engraved, is inserted into the projection groove in an upper side of the upper substrate;(b) mounting the light guide plate in the protrusion groove, the light guide plate having a thickness equal to a thickness of the protrusion groove; (c) foam-molding a foam on the upper substrate around the protrusion groove in a state where the upper substrate mounted with the light guide plate is inserted, the foam having a thickness equal to the thickness of each of the protrusion groove and the light guide plate; (d) applying an adhesive to upper surfaces of the protrusion groove, the light guide plate, and the foam; and (e) applying a transparent skin to the upper surfaces of the protrusion groove, the light guide plate, and the foam in a vacuum membrane press.

[0018] A method of manufacturing a soft upper panel for a switch assembly of a vehicle door according to claim 2 of the present invention is a method of manufacturing a soft upper panel for a switch assembly of a vehicle door in which a molding layer and a transparent layer are formed in a state where a light guide plate is attached to an upper substrate, the method comprising: (a) injection-molding the upper substrate such that a recessed groove and a projection groove communicate with each other, inserting a switch module into the recessed groove in a lower side of the upper substrate, and inserting a light guide plate, on which a symbol is engraved, into the projection groove in an upper side of the upper substrate; (b) mounting the light guide plate in the projection groove, the light guide plate having a thickness equal to a thickness of the projection groove;(c) foam-molding a foam on the upper substrate around the protrusion groove in a state where the upper substrate mounted with the light guide plate is inserted, the foam having a thickness equal to the thickness of each of the protrusion groove and the light guide plate; and (d) applying a transparent skin to upper surfaces of the protrusion groove, the light guide plate, and the foam in a vacuum membrane press, the transparent skin having a lower surface on which an adhesive is applied.

[0019] A method of manufacturing a soft upper trim for a switch assembly of a vehicle door according to an example not covered by the present invention is a method of manufacturing a soft upper trim for a switch assembly of a vehicle door in which a molding layer and a transparent layer are formed in a state where a light guide plate is attached to an upper substrate, the method comprising: (a) injection-molding the upper substrate such that a lower recessed groove and an upper recessed groove communicate with each other, a switch module is inserted into the lower recessed groove in a lower side of the upper substrate, and a light guide plate, on which a symbol is engraved, is inserted into the upper recessed groove in an upper side of the upper substrate; (b) mounting a light guide plate in the upper recessed groove;(c) injection-molding a transparent resin onto upper surfaces of the upper substrate and the light guide plate in a state where the upper substrate assembled with the light guide plate is inserted; and (d) ejecting a transparent ink onto an upper surface of the transparent ink.

[0020] In the above-mentioned method not covered by the invention, when mounting the light guide plate, the light guide plate may be mounted such that the upper surface of the light guide plate is positioned at a higher level than the upper surface of the upper substrate.

[0021] A soft upper trim panel for a switch assembly of a vehicle door according to claim 3 includes an upper substrate, a molding layer, and a transparent layer laminated together, wherein a through-hole into which a switch module is inserted is formed vertically in the upper substrate, a recessed groove having a diameter larger than a diameter of the through-hole is formed in a lower side of the upper substrate, a partition wall having a projection groove having a diameter larger than a diameter of the through-hole is formed to protrude from an upper side of the upper substrate, a light guide plate having a thickness equal to a thickness of the projection groove and having a symbol engraved therein is mounted in the projection groove, the molding layer includes a foam foam-molded around the partition wall to have a thickness,which is equal to the thickness of each of the protrusion groove and the light guide plate, and the transparent layer is a transparent skin attached to upper surfaces of the protrusion groove, the light guide plate and the foam.

[0022] In the soft upper panel according to claim 4, the light guide plate may include side plates and a top plate connecting upper surfaces of the side plates and engraved with a symbol, wherein a receiving groove into which an upper side of the switch module is inserted and received is further formed within a lower side of the light guide plate.

[0023] A soft upper trim panel for a switch assembly of a vehicle door according to an example not covered by the present invention includes an upper substrate, a molding layer, and a transparent layer that are laminated, wherein an upper recessed groove and a lower recessed groove are formed in the upper substrate to communicate with each other, a switch module is inserted in the lower recessed groove, a light guide plate is mounted in the upper recessed groove, and has a symbol engraved on an upper side thereof; the molding layer includes a transparent resin injection-molded on upper surfaces of the upper substrate and the light guide plate, and the transparent layer includes a transparent paint applied on an upper surface of the transparent resin.

[0024] In the soft upper cover according to the above-mentioned example not covered by the invention, the transparent resin may include a thermoplastic elastomer (TPE) material, the transparent resin may include a urethane material, the upper substrate may include polypropylene (PP), and the light guide plate may include polycarbonate (PC).

[0025] In the soft top cover according to the above-mentioned example not covered by the invention, the light guide plate may include side plates and a top plate connecting top surfaces of the side plates and engraved with a symbol, a receiving groove into which an top surface of the switch module is inserted and received may be further formed within a bottom surface of the light guide plate, and an top surface of the light guide plate may be positioned on a higher plane than an top surface of the top substrate. 3. Beneficial effects

[0026] The present invention has the following effects.

[0027] Since a foam and a transparent skin are laminated after a groove in which a switch module is installed is formed in a lower surface of an upper substrate, the continuity of a conventional transparent skin is maintained to ensure both a hidden property of the switch module and the smoothness of the transparent skin, thereby providing an excellent external appearance.

[0028] In particular, since symbols are displayed on an upper substrate at a specific position near a window, it is possible to check the symbols inside a vehicle as well as through the window from outside the vehicle. In particular, it is possible to check whether a door is properly locked (if symbols are formed on a middle substrate or a lower substrate, it is difficult or impossible for a driver to check the symbols inside or outside the vehicle).

[0029] Since a protrusion groove in which a light guide plate is mounted is implemented by a partition wall, the protrusion groove serves to prevent foam from adhering to a light guide plate when the foam is foam-molded.

[0030] Since a receiving groove in which an upper side of a switch module is received is formed in a center of a lower surface of a light guide plate, a thickness of an upper plate of the light guide plate is reduced by a thickness of the receiving groove to significantly improve transmittance, so that the receiving groove further improves the clarity of symbols and functions to further fix the switch module.

[0031] On the other hand, since a transparent resin and a transparent paint are applied, a separate process of drilling a hole in the transparent resin is not required, thus simplifying a process.

[0032] In the example not covered by the invention, since a transparent resin is implemented using a thermoplastic elastomer (TPE) material, an upper substrate is implemented using a polypropylene (PP) material, and a light guide plate is implemented using a polycarbonate (PC) material, the transparent resin has a very high affinity with the upper substrate and the light guide plate when they are injection molded.

[0033] In addition, since a transparent ink is implemented using a urethane material, the transparent ink has a high affinity with a thermoplastic elastomer (TPE) material.

[0034] In addition, since a light guide plate is mounted such that an upper surface is positioned at a higher level than an upper surface of an upper substrate, the upper surface of the light guide plate protrudes from the upper substrate in the form of a stepped portion to contribute greatly to fixing an injection-molded transparent resin. Brief description of the drawings Fig. 1 illustrates a view of a conventional soft door panel for a vehicle and cross-sectional views of upper and lower panels thereof; Fig. 2 and Fig. 3 are diagrams illustrating an inside of a front door provided with a conventional switch device for a vehicle, and illustrating states in which symbols of the switch device are displayed and not displayed; Fig. 4 is a series of flow diagrams illustrating a method of manufacturing a soft upper panel for a switch assembly for a vehicle door according to a first embodiment of the present invention; Fig. 5 is a series of flow charts showing a process for engraving symbols into a light guide plate made of Fig. 4 illustrate; Fig. 6 is a series of operation sequence diagrams of a hidden switch; and Fig. 7 is a series of flow diagrams illustrating a method of manufacturing a soft upper panel for a switch assembly for a vehicle door according to a second embodiment not encompassed by the present invention. DETAILED DESCRIPTION OF EMBODIMENTS

[0035] Hereinafter, embodiments of the present invention will be described in detail with reference to the accompanying drawings. Like parts are given the same reference numerals as conventional parts, and a detailed description thereof will be omitted.

[0036] Fig. 4 is a series of flow diagrams illustrating a method of manufacturing a soft upper panel for a switch assembly for a vehicle door according to a first embodiment of the present invention. Fig. 5 is a series of flow charts showing a process for engraving symbols into a light guide plate made of Fig. 4 illustrate. Fig. 6 is a series of operation sequence diagrams of a hidden switch. Fig. 7 is a series of flow diagrams illustrating a method of manufacturing a soft upper panel for a switch assembly for a vehicle door according to a second embodiment of the present invention. First embodiment

[0037] As in Fig. 4F, a soft upper panel 100 for a switch assembly of a vehicle door according to the present embodiment includes an upper substrate 200 on which a switch module 1 is mounted, a light guide plate 300 mounted on the upper substrate 200, and a foam 400 and a transparent skin 500 laminated on an upper surface of the upper substrate 200 around the light guide plate 300.

[0038] The upper substrate 200 is an injection-molded product made of an acrylonitrile butadiene styrene (ABS) material.

[0039] As in Fig. As illustrated in Figure 4A, a through-hole 210 is formed in the upper substrate 200 along a vertical center line thereof. A recessed groove 230 having a diameter larger than a diameter of the through-hole 210 is formed in a lower side of the upper substrate 200 to communicate with the through-hole 210.

[0040] The through hole 210 and the lower recessed groove 230 become a space in which the switch module 1 is received and mounted, as shown in Fig. 4F illustrates.

[0041] In addition, a partition wall 250 having a protrusion groove 240 with a diameter larger than the diameter of the through hole 210 is injection-molded to protrude from an upper side of the upper substrate 200.

[0042] The light guide plate 300 is mounted in the projection groove 240.

[0043] The light guide plate 300 may be made of a material bonded to engineering plastic, such as polycarbonate (PC), and may serve to diffuse light of a light-emitting diode (LED (not shown)) of a switch device 3 in the switch module 1.

[0044] As in Fig. As illustrated in Figure 5, patterns corresponding to a lock symbol 311 and an unlock symbol 313 are formed by cutting and removing the opaque ink 310 using a laser after an opaque ink 310 is applied (masked) to an upper surface of the light guide plate 300. A film on which symbols 315 are formed may be attached in place of the masking.

[0045] Therefore, when light is emitted through the light guide plate 300, the light can only pass through the lock and unlock symbols 311 and 313. Accordingly, a driver can view the lock / unlock symbols 311 and 313.

[0046] As in Fig. As illustrated in Figure 5, the light guide plate 300 includes side plates 301 and a top plate 303 connecting the upper surfaces of the side plates 301 and having symbols 311 and 313 engraved therein. A receiving groove 305, into which an upper side of the switch module 1 is inserted and received, is further formed within a lower side of the light guide plate 300.

[0047] Therefore, since a thickness h2' of the upper plate 303 is smaller than a thickness h2 of the side plate 301, light can be diffused more clearly and pass through the upper plate 303.

[0048] Since the upper side of the switch module 1 is received and mounted in the receiving groove 305, the additional fixation of the switch module 1 is much better.

[0049] Since the switch module 1 is inserted until a panel 5 of the switch module 1 is received on the recessed groove 230, the light guide plate 300 is not excessively pushed upward.

[0050] On the other hand, as in Fig. 4B, the partition wall 250 is injection-molded to protrude such that a thickness h1 of the partition wall 250 is equal to a thickness h2 of the light guide plate 300.

[0051] The partition wall 250 serves as a barrier wall configured to prevent the foam 400 from flowing to the light guide plate 300 when the foam 400 is foam molded, as described below.

[0052] As in Fig. As illustrated in Figure 4C, the foam 400 is foam molded on the upper substrate 200 around the partition wall 250.

[0053] The foam 400 is foamed such that a thickness h3 of the foam 400 is equal to the height h2 of the light guide plate 300 (h1=h2=h3).

[0054] When the foam 400, the partition wall 250, and the light guide plate 300 are formed to have the same height, a flat surface without a stepped portion is formed to prevent the transparent skin 500 from being folded or uneven due to a stepped portion when the transparent skin 500 is attached.

[0055] Foam 400 generally has a thickness of about 2 to 5 mm.

[0056] The foam 400 can be a polyurethane (PU) foam.

[0057] Since the foam 400 is not transparent, the foam 400 is foam-molded on the upper surface of the upper substrate 200 except for a location of the light guide plate 300.

[0058] As in Fig. 4E, the transparent skin 500 is attached to upper surfaces of the foam 400, the partition wall 250, and the light guide plate 300.

[0059] The transparent skin 500 may be a textured sheet and may be a thermoplastic olefin (TPO) or polyvinyl chloride (PVC) fabric or the like having a thickness of 0.5 to 1.0 mm or a thickness of 1.0 mm or more and a transmittance of about 10% to 15%.

[0060] TPO fabric is a material that is widely used as an interior material of a vehicle.

[0061] The switch module 1 includes a switch device 3 including LEDs corresponding to locking and unlocking, a printed circuit board (PCB) and the like, and a panel 5 on which the switch device 3 is mounted.

[0062] A method of manufacturing the above-described soft upper trim 100 for a switch assembly of a vehicle door is described with reference to Fig. 4 described.

[0063] As in Fig. 4A, an upper substrate 200 is injection-molded such that a recessed groove 230 and a protrusion groove 240 communicate with each other, a switch module 1 is inserted into the recessed groove 230 in a lower side of the upper substrate 200, and a light guide plate 300, on which symbols 315 are engraved, is inserted into the protrusion groove 240 in an upper side of the upper substrate 200.

[0064] As in Fig. 4B, the light guide plate 300 having a height equal to a height of the protrusion groove 240 is inserted and mounted into the protrusion groove 240 of the injection-molded upper substrate 200. In a state where the upper substrate 200 in which the light guide plate 300 is in the

[0065] projection groove 240 is mounted, is inserted as in Fig. 4C, a foam 400 having a thickness equal to the thickness of each of the protrusion groove 240 and the light guide plate 300 is foam-molded around a partition wall 250 having the protrusion groove 240.

[0066] As in Fig. As illustrated in Figure 4D, an adhesive 600 is applied to upper surfaces of the partition wall 250, the light guide plate 300, and the foam 400 having the same thicknesses.

[0067] As in Fig. 4E, a transparent skin 500 is applied to the upper surfaces of the partition 250, the light guide plate 300, and the foam 400, to which the adhesive 600 is applied.

[0068] The transparent skin 500 is attached in a membrane vacuum press.

[0069] The membrane vacuum press has a silicone film on its upper portion instead of a separate mold. When a peripheral portion of the membrane vacuum press is sealed after the membrane vacuum press is assembled, while a vacuum table on a lower portion of the membrane vacuum press vacuums and laminates a transparent skin, the silicone film serves to re-press the transparent skin.

[0070] As in Fig. 4F, the switch module 1 is mounted to the soft top panel 100 for a vehicle door switch assembly as manufactured above.

[0071] The soft upper panel assembled with the switch module 1 is coupled to a middle panel and a lower panel and is assembled and used as a final interior material of a vehicle door.

[0072] Accordingly, as in Fig. 6 illustrates that when a driver's hand approaches within 15 mm of the transparent skin 500 at a position where the hidden switch module 1 is mounted, a proximity sensor detects the hand and light from the LED is irradiated to display only the lock and unlock symbols 315 on the transparent skin 500.

[0073] When a desired symbol among the displayed lock / unlock symbols 315 is touched, the light of an unwanted symbol is turned off and the desired symbol is turned off after a few seconds and the operation of the switch module 1 is stopped.

[0074] To turn off the symbols 315, a light irradiation time of the LED can be set.

[0075] On the other hand, the transparent skin 500 having a lower surface on which an adhesive such as a hot melt adhesive is applied may be positioned and pressed on the upper surfaces of the protrusion groove 240, the light guide plate 300 and the foam 400, instead of the adhesive 600 made of Fig. 4D and apply it to the upper surfaces of the protrusion groove 240, the light guide plate 300 and the foam 400.

[0076] Although the symbols 315 have been described as lock / unlock patterns, the symbols 315 may also include an operation symbol for performing functions within a vehicle or a lighting symbol on which a lighting pattern for LED mood lighting is formed. Second embodiment (not covered by the present invention)

[0077] As in Fig. 7, a soft upper panel 100' for a switch assembly of a vehicle door according to the present second embodiment includes an upper substrate 200' on which a switch module 1 is mounted, a light guide plate 300 mounted on the upper substrate 200', a transparent resin 400' attached to the upper surfaces of the light guide plate 300 and the upper substrate 200, and a transparent skin 500' vacuum-pressed on an upper surface of the transparent resin 400'.

[0078] The upper substrate 200' is a component injection molded using polypropylene (PP).

[0079] As in Fig. As illustrated in Figure 7A, a through-hole 210 is formed along a vertical centerline of the upper substrate 200'. A lower recessed groove 230 having a diameter larger than a diameter of the through-hole 210 is formed in a lower side of the upper substrate 200' to communicate with the through-hole 210.

[0080] In addition, an upper recessed groove 240' having a diameter larger than the diameter of the through-hole 240 is formed in an upper side of the upper substrate 200'. As shown in Fig. As illustrated in Figure 7B, the light guide plate 300 is mounted in the upper recessed groove 240`.

[0081] The structure and function of the light guide plate 300 of the second embodiment are similar to those of the light guide plate 300 of the first embodiment. As shown in Fig. 7B, however, the light guide plate 300 may be mounted with a thickness h2 that is greater than a thickness h1 of the upper recessed groove 240', that is, an upper surface 302 of the light guide plate 300 may protrude further compared to an upper surface 201 of the upper substrate 200'.

[0082] An upper side of the light guide plate 300, which is mounted to protrude, serves as a stepped shutter portion to completely prevent a phenomenon in which the transparent skin 400' is picked up, is slippery, and is peeled off after it is injection-molded.

[0083] As in Fig. 7C, the transparent resin 400' is injection-molded onto the upper surfaces 201 of the upper substrate 200' and the upper substrate 302 of the light guide plate 300.

[0084] The transparent resin 400' can be implemented using a thermoplastic elastomer (TPE) material having a thickness of about 1.0 to 2.5 mm and a transmittance of 64%.

[0085] In addition, the TPE material has a high affinity with polypropylene (PP) and polycarbonate (PC) materials.

[0086] Since the transparent resin 400' covers the entire upper surface 201 of the upper substrate 200' and the entire upper surface 302 of the light guide plate 300 as described above, even when the transparent paint 500' is applied, the transparent paint 500' can be prevented from becoming wrinkled or uneven due to a stepped portion.

[0087] After the transparent resin has been injection molded for 400' as in Fig. As illustrated in Figure 7D, the transparent paint 500' is applied to the upper surface of the transparent resin 400'.

[0088] The transparent color 500' has a transmittance of about 5% after light has passed through the transparent resin 400'.

[0089] The transparent paint 500' can be a urethane paint that has a permeability and cushioning property.

[0090] A method of manufacturing the above-described soft upper trim 100' for a switch assembly of a vehicle door is described with reference to Fig. 7 described.

[0091] As in Fig. 7A, an upper substrate 200' is injection-molded such that a lower recessed groove 230 and an upper recessed groove 240' communicate with each other, a switch module 1 is inserted into the lower recessed groove 230 in a lower side of the upper substrate 200, and a light guide plate 300, on which symbols 315 are engraved, is inserted into the upper recessed groove 240 in an upper side of the upper substrate 200.

[0092] As in Fig. 7B, the light guide plate 300 is inserted and mounted into the upper recessed groove 240' of the injection-molded upper substrate 200'.

[0093] In this case, the light guide plate 300 is mounted such that an upper surface 302 of the light guide plate 300 is positioned at a higher level than an upper surface 201 of the upper substrate 200'.

[0094] In a state where the upper substrate 200` in which the light guide plate 300 is mounted in the upper recessed groove 240` is inserted as shown in Fig. As illustrated in Figure 7C, a transparent resin 400' is injection-molded onto upper surfaces of the upper substrate 200' and the light guide plate 300.

[0095] After the transparent resin has been injection molded for 400' as in Fig. As illustrated in Figure 7D, a transparent ink 500' is ejected and applied to an upper surface of the transparent resin 400'.

[0096] As in Fig. 7E, the switch module 1 is mounted to the soft upper panel 100' for a vehicle door switch assembly as manufactured above. (Description of the symbols) 100, 100' soft upper panel for a vehicle door switch assembly 1 switch module 3 switches 5 aperture 200, 200' upper substrate 210 through hole 230 recessed groove 240 projection groove 250 partition wall 300 light guide plate 305 mounting groove 315 locking and unlocking symbols 400 foam 500 transparent skin 600 Adhesive 230' lower recessed groove 240' upper recessed groove 400' transparent resin 500' transparent color

Claims

[1] A method of manufacturing a soft upper panel (100) for a switch assembly of a vehicle door in which a molding layer and a transparent layer are formed in a state in which a light guide plate (300) is attached to an upper substrate (200), the method comprising: (a) injection-molding the upper substrate (200) such that a recessed groove (230) and a projection groove (240) communicate with each other, a switch module is inserted into the recessed groove (230) in a lower side of the upper substrate (200), and a light guide plate (300) in which a symbol is engraved is inserted into the projection groove (240) in an upper side of the upper substrate (200); (b) mounting the light guide plate (300) in the projection groove (240), the light guide plate (300) having a thickness equal to a thickness of the projection groove (240); (c) foam-molding a foam (400) on the upper substrate (200) around the protrusion groove (240) in a state where the upper substrate (200) mounted with the light guide plate (300) is inserted, the foam (400) having a thickness equal to the thickness of each of the protrusion groove (240) and the light guide plate (300); (d) applying an adhesive (600) to upper surfaces of the projection groove (240), the light guide plate (300) and the foam (400); and (e) applying a transparent skin (500) to the upper surfaces of the projection groove (240), the light guide plate (300) and the foam (400) in a vacuum membrane press. [2] A method of manufacturing a soft upper panel (100) for a switch assembly of a vehicle door in which a molding layer and a transparent layer are formed in a state in which a light guide plate (300) is attached to an upper substrate (200), the method comprising: (a) injection-molding the upper substrate (200) such that a recessed groove (230) and a projection groove (240) communicate with each other, a switch module is inserted into the recessed groove (230) in a lower side of the upper substrate (200), and a light guide plate (300) in which a symbol is engraved is inserted into the projection groove (240) in an upper side of the upper substrate (200); (b) mounting the light guide plate (300) in the projection groove (240), the light guide plate (300) having a thickness equal to a thickness of the projection groove (240); (c) foam-molding a foam (400) on the upper substrate (200) around the protrusion groove (240) in a state in which the upper substrate (200) mounted with the light guide plate (300) is inserted, the foam (400) having a thickness equal to the thickness of each of the protrusion groove (240) and the light guide plate (300); and (d) applying a transparent skin (500) to upper surfaces of the projection groove (240), the light guide plate (300), the foam (400) in a vacuum membrane press, the transparent skin (500) having a lower surface on which an adhesive (600) is applied. [3] A soft upper panel (100) for a switch assembly of a vehicle door, the soft upper panel comprising an upper substrate (200), a molding layer and a transparent layer which are laminated, wherein: a through hole (210) into which a switch module is inserted is formed vertically in the upper substrate (200); a recessed groove (230) having a diameter larger than a diameter of the through hole (210) is formed in a lower side of the upper substrate (200); a partition wall (250) having a protrusion groove (240) with a diameter larger than a diameter of the through hole (210) is formed to protrude from an upper side of the upper substrate (200); a light guide plate (300) having a thickness equal to a thickness of the projection groove (240) and having a symbol engraved therein is mounted in the projection groove (240); the molding layer includes a foam (400) foam-molded around the partition wall (250) to have a thickness equal to the thickness of each of the projection groove (240) and the light guide plate (300); and the transparent layer is a transparent skin (500) attached to upper surfaces of the projection groove (240), the light guide plate (300) and the foam (400). [4] The soft top cover (100) according to claim 3, wherein the light guide plate includes side plates and a top plate connecting upper surfaces of the side plates (301) and having a symbol engraved thereon, wherein a receiving groove (305) into which an upper side of the switch module is inserted and received is further formed within a lower side of the light guide plate (300).

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