CONTROL UNIT

Abstract

A control unit (10) for a device, wherein the control unit (10) comprises: a component-supporting element (14) provided with at least one electronic component (30, 32, 34) configured to provide a function of the device; wherein the component-supporting element (14) is formed from a material that is flexible at least during the assembly of the control unit; a second element (18) that defines a user interaction area visible to a user of the device in use; an injection-molded mold layer (22) that encapsulates at least part of the electronic component or each component (30, 32, 34); wherein the second element (18) is provided with at least one further electronic component (30, 32, 34), such that the electronic component(s) (30, 32, 34) or each of the electronic components (30, 32, 34) are located on the component-supporting element (14) and the at least one further electronic component (30, 32, 34) on the second element (18) are arranged between the component-supporting element (14) and the second element (18) within the injection-molded mold layer (22); and wherein the user interaction surface is configured to receive a user command, and wherein the electronic component or components (30, 32, 34) are functional in response to the user command, the control unit (10) further features: a piezoelectric layer adjacent to the user interaction surface to enable control of the electronic component (30, 32, 34) when the user applies a user command in the form of pressure to the user interaction surface.

Description

TECHNICAL AREA

[0001] The present disclosure relates to a control unit for a device. In particular, but not exclusively, the invention relates to a control unit that includes electronic components and / or microprocessors for operating the device. The control unit has a specific, but not exclusive, application in a vehicle. Aspects of the invention relate to a control unit, a device, and a manufacturing method. BACKGROUND

[0002] Modern motor vehicles have numerous different systems and subsystems that require electronic control units (ECUs) to operate and control their functionality. Examples of the required control units include the various airbags distributed throughout the vehicle cabin, interior lights, front and rear seats, the entertainment system and / or DVD player, parking assistance systems, various motion and other sensors, power steering, off-road and navigation systems, to name just a few. Additional electronic control units are also needed to manage the powertrain and the vehicle's engine.

[0003] As vehicle complexity increases, the need for so many control units presents a challenge for vehicle manufacturers, as space must be found to house these units within the vehicle. Some current vehicles can contain up to 80 different control units distributed throughout the vehicle. In addition to the space constraints, the wiring of the devices and their added weight are also drawbacks.

[0004] A particular challenge with existing control units is the limitation of their shape and size, which restricts their installation location. Traditionally, control units consist of a circuit board with various electronic components and wiring, housed in a rigid casing. For aesthetic and safety reasons, these units must be concealed within the vehicle and are often located behind the cabin trim. However, space is limited in these areas, and the inflexible design of the control unit packaging makes it difficult to install them in tight spaces.

[0005] From DE 11 2017 001 884 T5, a method for manufacturing a control panel intended for installation in the interior of a vehicle is known, comprising the steps of: providing a film with a conductive track and at least one piezoelectric element, forming a control arrangement by attaching the at least one piezoelectric element to the film, providing a printed circuit board, and attaching the control arrangement to the printed circuit board. The document also refers to a trim element comprising a carrier and a control panel mounted on the carrier.

[0006] From WO 2017 / 178 702 A1, an integrated multilayer arrangement for an electronic device is known, comprising: a first substrate film configured to incorporate electrical features on at least one first side; a second substrate film configured to incorporate electrical features on at least one first side, the first sides of the first and second substrate films being configured to face each other; at least one electrical feature on the first side of the first substrate film; at least one further electrical feature on the first side of the second substrate film; and a molded plastic layer between the first and second substrate films, which embeds the electrical features at least partially in the first sides thereof. A corresponding manufacturing process is also known.

[0007] From US patent 2016 / 0 192 474 A1, a multilayer structure for electronic devices is known, comprising: a flexible substrate film for receiving electronic devices, a number of electrical elements provided for the flexible substrate film, preferably by a printed electronics element and / or a surface mount, a protective layer laminated at least to the first surface of the substrate film, wherein the protective layer is configured to mask a perceptible physical deviation of the substrate, such as an uneven surface profile or coloration, substantially at the location of the electrical elements from external perception, optionally the visual perception and / or tactile inspection carried out via the protective layer, and a plastic layer formed over at least the second surface of the substrate film, which is opposite the first surface.Furthermore, the document reveals a corresponding manufacturing process.

[0008] From US patent 10,055,629 B2, a fingerprint sensor is known which consists of a piezoelectric substrate and an electrode on the piezoelectric substrate. The electrode comprises a first electrode and a second electrode on at least one of the surfaces of the piezoelectric substrate and on a surface opposite that surface. The electrode includes a node region where the first electrode intersects the second electrode. The node region transmits and receives a signal from an object that comes into contact with the node region or approaches the node region in a direction along the piezoelectric substrate. The fingerprint sensor comprises a substrate that includes a first, second, third, and fourth region. At least one of the first and second electrodes is located from the first region to the third region, and a chip connected to the first and second electrodes is provided in the fourth region.

[0009] The present invention was developed to mitigate or overcome at least some of the problems mentioned above. SUMMARY OF THE INVENTION

[0010] Aspects and embodiments of the invention constitute a control unit for a device, a apparatus, a manufacturing process and a vehicle, as required in the attached claims.

[0011] According to one aspect of the present invention, a control unit for a device is provided, wherein the control unit comprises a component-supporting element provided with at least one electronic component configured to provide a function of the device; wherein the component-supporting element is formed from a material that is pliable or flexible at least during the assembly of the control unit; and an injection-molded layer enclosing at least a part of the electronic component or each electronic component.

[0012] The control unit has the advantage of being easy to manufacture and, in its final version, offers a lightweight yet robust control unit that takes up little space in the device in which it is used.

[0013] A further advantage of the invention is that, since the component-supporting element is formed from a material that is pliable or flexible, at least during the assembly phase of the control unit, the component-supporting element can be manipulated to assume a variety of different shapes depending on the requirements of the final product. For example, the control unit does not have to be flat and can be shaped to have a curved, wavy, or non-planar profile.

[0014] Furthermore, as part of the manufacturing process, since the injection-molded layer is formed over the component-bearing element, the layer and the element can be shaped together to define the required shape for the final product.

[0015] Depending on the material chosen for the component's supporting element, the application of the injection-molded layer causes the two materials to tend to fuse together, effectively embedding, fusing, or integrating the electronics into the structure's materials in the final product. In other words, in the final product, the components appear to be suspended within the structure, formed between the injection-molded layer and the supporting element. In some embodiments, the layered structure of the fully assembled control unit may no longer consist of separate layers at all. The structural electronics thus formed become part of the control unit's load-bearing capacity.

[0016] In one embodiment, the component-supporting element can be formed from a material that is flexible during the assembly phases but solidifies or becomes stiffer after the control unit is assembled, thus defining a rigid end product. Alternatively, the material from which the electronically supporting component can be formed can retain a certain degree of flexibility in its final shape after the control unit is fully assembled, so that the end product is, for example, flexible or bendable.

[0017] The invention thus offers a highly versatile control unit structure that can be adapted for use in a wide variety of applications. Due to the flexibility of the control unit, it can, for example, at least during the manufacturing phase, be adapted to a shape that can be used as a glove compartment lid or an overhead control panel, which generally has a curved surface.

[0018] The control unit has a specific application in a vehicle, wherein at least one electronic component is configured to provide a function of the vehicle, for example a function in the form of controlling the lighting system, the heating system, the entertainment system, the seating system, the airbag system, the sunroof or the window.

[0019] Other embodiments provide that the control unit forms a panel of a household appliance, such as electrical items in the form of washing machines, stoves or dishwashers and the like.

[0020] When used in a vehicle, the control unit offers the advantage of being easy to manufacture and, in its final version, providing a lightweight yet robust unit that takes up little space within the vehicle. This is particularly useful in modern vehicles with high levels of functionality and an ever-increasing need for additional control functions. Furthermore, each electronic component is at least partially protected by the injection-molded layer that encapsulates the sensitive electronic components and circuits. The user command can be the pressing of a button, a capacitive touch command such as touching or swiping with a finger, a gesture, or a voice activation command received by a microphone. The vehicle function can be a control signal to a component of the printed circuit board, such as turning on a light.

[0021] In one embodiment, the control unit includes a presentation area that is visible to a user of the device used.

[0022] In one embodiment, the component-bearing element defines the presentation area.

[0023] In another embodiment, the presentation area defines a user interaction area for receiving a user command, and the component-carrying element is operable in response to the user command.

[0024] It may be advantageous to incorporate a piezoelectric layer adjacent to the user interaction surface to enable the control of the at least one electronic component when the user applies a user command in the form of pressure to the user interaction surface in order to control the electronic component(s).

[0025] The control unit can include a component-bearing surface that supports the electronic component or components that can form part of a printed electronic circuit.

[0026] For example, in one embodiment, the component-bearing surface can be located on the back of the component-bearing element facing the presentation area. This embodiment offers the advantage that only a single element is required to define both the presentation area on one side and the components on the other (i.e., the component-bearing surface). The control unit of this embodiment is particularly thin and lightweight and can be formed in a single-stage injection molding process to create the injection-molded layer.

[0027] The control unit can include a second element that is spaced apart from the component-bearing element by the injection molding layer to define a three-part structure for the control unit.

[0028] The second element can define the presentation area.

[0029] The component-bearing element and / or the second element can be in the form of a pre-formed element, i.e., an element that is formed before a step to form the injection-molded layer.

[0030] The three-part structure of the component-bearing element, the second element and the injection-molded layer in between is particularly suitable when an A-surface, with which the user interacts at the front of the control unit, and a B-surface at the back of the control unit, which carries the electronic component or components, are required.

[0031] In another example, the second element can be provided with at least one additional electronic component, such that the electronic component(s) on the component carrier element and the at least one additional electronic component on the second element are clamped between the component carrier element and the second element within the injection molded layer.

[0032] This arrangement offers the advantage that the electronic components are distributed across different surfaces, which can have benefits in terms of space and / or heat dissipation. The arrangement offers a particular advantage when the control unit is operated via gesture control, so that the components actuated by gesture control are located on the back of surface A, while other components can be moved from these and placed on the other element.

[0033] In one embodiment, the electronic component can form part of a printed electronic circuit, which can include a plurality of conductor tracks for power transmission to at least one electronic component of the printed electronic circuit.

[0034] The conductor tracks, together with the user interaction surface, can act as electrodes of a capacitor to provide a capacitive touch control function in response to the user command.

[0035] The capacitive touch control offers the user of the control unit a fast, effective and sophisticated operating experience.

[0036] In one embodiment, a larger number of conductor tracks can be provided on the printed electronic circuit than is required to supply sufficient current to the electronic components of the printed electronic circuit, thus ensuring trace redundancy in the event of a break and / or failure of one or more conductor tracks.

[0037] The advantage of this track redundancy is that, for example, any track break or malfunction caused by damage during the injection molding process is compensated for by providing additional tracks that can still supply the necessary current to the electronic components of the circuit. This is particularly advantageous because injection molding must be carried out at high temperatures.

[0038] In particular, but not exclusively, a larger number of conductor tracks on the printed electronic circuit can be provided in areas near a gate for injecting a material of the injection molding layer during the assembly of the control unit.

[0039] The control unit can include an additional layer on the user interaction surface to give the control unit an aesthetic finish.

[0040] The additional layer can be a veneer that complements a surface of the device in which the control unit is used, for example, the interior trim of a vehicle. "Complements" means that the veneer can match or otherwise complement the rest of the interior of the vehicle in which the control unit is installed. The veneer can be a wood surface, a plastic surface, a leather-effect surface, or any other surface commonly found, for example, in a vehicle cabin.

[0041] The additional layer can be a protective layer.

[0042] For example, the additional layer could be another injection-molded layer.

[0043] The additional layer can be provided with one or more cutouts to create a greater sense of depth when the user views the additional layer through the cutouts (e.g., if the cutouts have different depths).

[0044] The control unit may include a thermally conductive element that is at least partially encapsulated in the injection molded layer and configured to dissipate heat to or from the at least one electronic component.

[0045] The use of a thermally conductive layer within the control unit offers several advantages. First, during the assembly of the control unit, the high temperatures associated with the injection molding process, which can lead to heat build-up in the electronic components and thus potentially damage the circuit, are dissipated, depending on where the thermally conductive element is thermally connected, either to a remote component or to the circuit carrier and / or a second element. The remote component could, for example, be part of the injection molding tooling, or alternatively, the thermally conductive layer could be in contact with the component carrier and / or the second element, conducting heat to these elements. Second, during operation, as the electronic components and the circuit heat up, the heat is dissipated via the thermally conductive element.

[0046] In this way, unwanted heat energy from the electronic components can be used to heat the ambient air near the control unit. As a concrete example, if the control unit occupies part of the interior of a vehicle cabin, heat energy from the circuit-supporting element and / or the second element can be transferred to the cabin environment via thermal radiation or convection. This provides local heating within the vehicle cabin, thereby reducing the load on the vehicle's HVAC system.

[0047] The control unit can include at least one gate through which the injection molding layer material is injected during the manufacture of the control unit.

[0048] It is helpful to locate at least one gate so that it is away from electronic components that are active components, so that material injected through the gate during the manufacture of the control unit, due to the high pressures and temperatures associated with the injection molding process, damages the structure less.

[0049] The component-bearing element and / or the second element may include a pre-formed element, i.e., an element that is formed before the formation of the injection-molded layer.

[0050] If the control unit forms a control unit for a vehicle, the control unit may include at least one electronic component configured to control one or more of the following vehicle functions: an airbag, an entertainment system, a sound system, a window, a seating system, a lighting system.

[0051] According to a further aspect of the invention, a device with a control unit according to the first aspect is provided, wherein the device has at least one function under the control of the control unit.

[0052] The device can, for example, be designed in the form of a vehicle.

[0053] According to a further aspect of the invention, a method for manufacturing a control unit for a device is provided, wherein the method comprises preforming a circuit carrier element in a first preforming step, providing at least one electronic component on the circuit carrier element to provide a function of the device in use, and injecting an injection-moldable material onto the at least one electronic component to enclose the at least one electronic component at least partially in an injection-molded layer.

[0054] For example, the process can include preforming a second element in a second preforming step and, after the first and second preforming steps, injecting the injectable material between the component-bearing element and the second element to at least partially encapsulate the electronic component(s) in the injection-molded layer.

[0055] In this way, a simple and convenient manufacturing method can be achieved to provide a lightweight, robust and cost-effective control unit for numerous applications.

[0056] Within the scope of this application, it is expressly provided that the various aspects, embodiments, examples, and alternatives set forth in the preceding paragraphs, in the claims, and / or in the following descriptions and drawings, and in particular their individual features, may be adopted independently or in any combination. That is to say, all embodiments and / or features of an embodiment may be combined in any way and / or combination, unless these features are incompatible. The applicant reserves the right to amend an originally filed claim or to file a new claim accordingly, including the right to amend an originally filed claim to be dependent on another claim and / or to include a feature of another claim, even if it was not originally claimed in this manner. BRIEF DESCRIPTION OF THE DRAWINGS Fig. is a schematic diagram of a well-known vehicle to illustrate the positions of various electronic control units around the vehicle. One or more embodiments of the invention will now be described by way of example only with reference to the accompanying drawings, in which: Fig. is a side view of a vehicle with which embodiments of the invention can be used; Fig. is a perspective view of the vehicle interior in Fig. , to illustrate positions where the control unit of the embodiments of the invention can be used; Fig. is an exploded view of a control unit of a first embodiment of the invention, which is used in a vehicle of the type described in the Fig. can be used of the type shown; Fig. is a top view of a printed electronics layer that is part of the control unit in Fig. is; Fig. is a schematic cross-section of the control unit in Fig. , which was manufactured using the single-shot injection molding process; Fig. is a schematic cross-section of a control unit of a second embodiment, which was also manufactured using a single injection molding process; Fig. is a schematic cross-section of a control unit of a third embodiment, which was formed using the twin-shot injection molding process; Fig. is a schematic cross-section of a control unit of a fourth embodiment, which was formed using a single injection molding process; Fig. is a schematic cross-section of a control unit of a fifth embodiment, which was formed using a single injection molding process; Fig. is a perspective view of a control unit of a sixth embodiment with only partial encapsulation of the printed electronic layer; Fig. is a schematic cross-section of a control unit of a seventh embodiment, which includes a heat sink arrangement; Fig. is a schematic cross-section of a control unit of an eighth embodiment with a different heat sink arrangement than in Fig. depicted; Fig. is a schematic cross-section of a control unit of a ninth embodiment, in which the profile of the control unit is curved; Fig. is a schematic perspective view of a control unit formed by a lamination process; Fig. is a schematic cross-section of a printed electronic layer that can be used in embodiments of the invention; Fig. is a perspective view of a section of the printed electronic layer in Fig. , to show a supporting structure of it; and Fig. is a perspective view of a section of a printed electronic layer in an alternative embodiment to the one in Fig. shown to represent an alternative support structure for the printed electronic layer. DETAILED DESCRIPTION

[0057] With reference to Fig. The various functions within the vehicle cabin of a modern vehicle, together with the engine and the drivetrain, require that numerous control units (or controllers) are located in an already limited installation space within the vehicle. Fig. This illustrates only some of the possible locations for the control units, some of which are marked with the reference number 10, which can be distributed throughout the vehicle 12. For example, it is not uncommon for a vehicle 12 to be equipped with more than 70 such control units 10, including those for the cabin lighting systems, airbags, sunroof, roof blinds, windows, front and rear seats, parking sensor system, various other sensor systems around the vehicle, and the vehicle entertainment system.

[0058] Fig. Figure 100 is a side view of a vehicle 100, with which embodiments of the invention can be used to offer advantages over known vehicles. The interior of the vehicle is shown in Figure 100. Fig. Figure 10a illustrates two possible positions for the control unit of the invention. In one position, the control unit is configured as an overhead control unit, called 10a, which can control various vehicle functions, including lighting, sunroof, and / or blinds. In another position, the control unit takes the form of a cover or lid for a glove compartment, which has a curved surface profile. The glove compartment control unit can control various vehicle functions, including, for example, lighting, seating, heating, audiovisual, and satellite navigation functions.

[0059] Fig. Figure 14 is an exploded view of a first embodiment of the control unit 10 of the invention, which, in contrast to existing control units, offers a compact and relatively lightweight structure that can be more easily accommodated in the vehicle cabin. The control unit 10 comprises three elements: a first element 14, which defines a user interaction surface in the form of a presentation area that is visible to the user when the control unit 10 is installed in its operating location. The presentation area can be referred to as the A-surface 16 of the unit. The user can also interact with the presentation area by touching it.

[0060] The control unit 10 further comprises a second element 18, which defines a B-surface 20 of the unit, and an intermediate element in the form of an injection-molded layer 22, which is positioned between the first and second elements 14, 18. Typically, reference is made to an “A-surface” that is presented to and / or with which a user of the vehicle interacts, e.g., to trigger the control of a function in the vehicle, while a “B-surface” is a non-interacting surface that is normally hidden from the user’s view. The A- and B-surfaces can be defined by opposing surfaces of the same element, or as in Fig. represented by separate elements 14, 18, which are separated from each other.

[0061] The following description shows that either the first or the second element can form the component-bearing element of the control unit 10 (i.e., the element on which the electronic components are provided). The term "element" can be used for any part, element, layer, or other component of the control unit.

[0062] The first and second elements 14, 18 are generally plate-shaped elements, but in other configurations they can be implemented as thinner elements or simply as a layer of material. The first and second elements 14, 18 are preformed elements that are pliable and flexible, at least during the assembly phase of the control unit, as described in more detail below. The preformed first and second elements 14, 18 are placed in the injection mold prior to the injection molding process, which forms the mold layer 22.

[0063] With reference to Fig. The A-surface is defined by a first thermoformed element 14, which is pre-formed by first heating a plastic sheet to a pliable temperature and then placing the pliable sheet into a mold so that the plastic material takes the shape of the mold before being cooled. The graphic features 24 (only a few of which are labeled) are applied to the A-surface 16 to provide features such as symbols or icons that indicate to the vehicle user how to control various functions of the finished control unit. Typically, the graphic features are applied by placing a printed layer into the mold to define the required graphic symbols and icons.The A-surface features a three-dimensional finger track or groove 17 into which a user can place their finger and guide it along the track, optionally applying pressure to the surface or initiating control of a vehicle function by capacitive touch, as described in more detail below. The A-surface 16 typically defines a visible surface in the vehicle cabin with which the user interacts. For example, the A-surface may be a surface of an armrest, an overhead control panel, a tray table, a seat control switch package, a glove compartment lid, or a portion of the vehicle instrument panel.

[0064] Surface B 20 is defined by a second thermoformed element 18, which is designed as a flexible element, at least during the manufacturing steps of the control unit 10. The second element 18 is formed in the same manner as previously described for the first element 14, and a variety of active and / or passive electronic components and printed circuits or wires are applied to the element 18 using known techniques. Typical passive components include resistors, capacitors, inductors, transformers, and diodes, while typical active components are those that act on a current source, such as amplifiers, switches, light-emitting diodes (LEDs), integrated circuits, memory devices, and microcontrollers.Typically, the B-surface 20 can be equipped with one or more of the following features: an integrated circuit, a microprocessor, light-emitting diodes (LEDs), user-interactive components such as pressure-sensitive traces, grid sensors, resistors, antennas, capacitors, sensors, quartz clocks, inductors, and conductive prints or traces for power transmission. Known techniques for printing on the wires and traces on the B-surface 20 include screen printing, flexographic printing, gravure printing, offset lithography, inkjet printing, aerosol deposition printing, or laser printing.

[0065] As pre-formed, thermoformed parts, the first and second elements 14, 18 are lightweight and robust and can be formed with an aesthetically pleasing shape, contour, and / or surface. This applies particularly to the A-surface 16, which provides the user interaction surface and is visible to the user in the vehicle cabin. The thermoforming process also makes it possible to achieve a wide range of different shapes for the elements 14, 18. For example, the first and second elements 14, 18 are formed from materials that are flexible during the assembly phases to give them the desired shape for the injection mold. In other embodiments, the first and second elements 14, 18 can be formed from materials and / or have a thickness that retains a certain degree of flexibility or pliability even when the control unit 10 is fully assembled.

[0066] In the present embodiment, the first and second elements 14, 18 are generally flat with a slight curvature on their upper surface. In other embodiments, the elements may, for example, be at least partially more fully curved or rounded, determined by the shape of the available living space they are intended to occupy in the vehicle. Typical materials from which the first and second elements 14, 18 are formed are polycarbonate materials or thermoplastic polymer resins such as polyethylene terephthalate (PET). Other examples of injection-molded thermoplastic polymers are polyphenylene sulfide (PPS), polyethersulfone, acetals, polypropylene, polyetherimide (PEI), polyethylene, polyphenylene oxide (PPO), acrylonitrile butadiene styrene, polyurethanes (PUR), thermoplastic elastomers, polyphthalamide (PPA), polyethylene naphthalate (PEN), and polyimide (PI), including Plexiglas.

[0067] In other embodiments of the invention, the first and second elements 14, 18 can be manufactured as deep-drawn elements, in contrast to thermoformed elements. Other preforming methods can also be used to produce the "preformed" elements 14, 18 before the injection molding process.

[0068] Fig. shows an example of a B-surface 20, which forms part of the second element 18 of the control unit 10 in Fig. can form. If, on-site in the vehicle, the B-surface 20 can define at least part of an overhead control panel for controlling various lighting functions in the cabin ceiling and for operating a vehicle sunroof and / or roof blinds, as mentioned above.

[0069] Surface B 20 is equipped with a printed electronic layer (labeled as 29 in Fig. ) provided with a first set 30 of four LEDs arranged horizontally in a first zone (top left) of the surface, a second set 32 ​​of three LEDs arranged vertically in a second zone directly to the right of the vertical center line of the surface, and a third set 34 of LEDs arranged in an arc adjacent to the second zone. It should be noted that the use of the terms horizontal and vertical in this description refers to the orientation shown in the illustrations but is not intended as a limitation.

[0070] The positions of the first, second, and third zones on surface B 20 correspond to the associated areas on surface A 16, which are provided with graphic features to identify the positions of the underlying zones when elements 14 and 18 are assembled into a "stack," as shown in Fig. The four LEDs 30 in the first zone can typically be implemented as low-intensity LEDs to create ambient lighting on the vehicle's ceiling or to illuminate other features of the control unit. The three LEDs 32 in the second zone can typically be implemented as higher-intensity LEDs that provide work lights for the vehicle. Various other light sources can be integrated into the control panel, including LEDs to create ambient lighting effects, LEDs to illuminate hidden or illuminated functions, emergency call functions (E-call functions) or breakdown call functions (B-call functions), and LEDs to illuminate symbols or graphic functions that provide the user with information on various functions of the control unit 10.

[0071] The B surface 20 is further equipped with a hybrid integrated circuit 36 ​​for controlling and operating the various electronic components 30, 32, 34.

[0072] Conductive traces or traces (two of which are designated by 38) are printed onto different areas of the B surface to supply power to the various components 30, 32, 34. In practice, for reasons that will be explained later, a larger number of traces may be provided than is required for each component 30, 32, 34. The conductive traces 38 include copper traces (e.g., as part of the hybrid integrated circuit 36) that establish fast connections to the microcontrollers and microprocessors of the hybrid integrated circuit 36, and silver traces that carry power from the hybrid integrated circuit 36 ​​to the other components (e.g., components 30, 32, 34) of the printed electronic layer. The substrate for the printed electronic layer can be in the form of polyester (PET), polyethylene naphthalate, polyimide, or Plexiglas.

[0073] A grid scanning area 40 is provided in a three-dimensional groove formed along the upper edge of the B-surface 20, corresponding to the position of the aforementioned three-dimensional groove in the A-surface. The groove 40 is shaped to accommodate the groove formation 26 of the A-surface when the elements 14, 18 are assembled. In use, the sliding movement of the user's finger along the groove 26 provides a variable control function or a "slider" function (e.g., with a piezoelectric or capacitive touch function), which can be used in particular to control the opening of a vehicle sunroof, as described in more detail below.

[0074] Openings, also called "gates" 44, are provided in the center of surface B 20 and in each of the four outermost corners. A molding material is injected into these openings to form the third element 22 between the first and second elements 14, 18. The first and second elements 14, 18 are first placed, as previously described, into appropriate injection molds with their different properties. Then, the material for the intermediate element 22 is injected through the gates 44 into the cavity between the outer elements 14, 18. Typically, the material injected between the first and second elements 14, 18 is a polycarbonate material or another material suitable for injection molding. Such polycarbonate materials are very robust and can be transparent.The material is injected into the cavity at high temperature and high pressure and then cooled so that the material takes on the shape of the cavity between the first and second element 14, 18 to fill the space in . Fig. to complete the clearly illustrated three-layer structure of the control unit 10. Other suitable materials for the mold layer are most polymers (resins), including thermoplastics, thermosets, and elastomers. The materials selected for the first and second pre-formed elements 14, 18 can be materials that are flexible or foldable in the final state, or, depending on the application, have a stiffer structure.

[0075] The position of the gates 44 is an important feature of the assembly, as the gates must be positioned in areas where the high pressures and temperatures associated with the injection molding process do not damage the more delicate and sensitive electronic components on surface B 20. As an example, with reference to Fig. From a manufacturing perspective, the central gate position is advantageous because it allows for a uniform distribution of the injection molding material between the first and second elements 14, 18, defining a mold layer 22 with a substantially uniform thickness. The gates are positioned such that the flow pressure is distributed evenly between the surfaces of elements 14, 18. However, this places the injection point of the central gate in close proximity to some of the components on surface 20 (e.g., the LEDs and the integrated circuit). In other embodiments, it may be possible to completely eliminate the central gate 44 and rely solely on the corner gates to introduce the injection molding material between elements 14, 18.However, a balance must be struck between the higher pressures required to inject the material into the central area between the elements to achieve a uniform layer across the entire surface, and the need to protect sensitive electronic components on surface B from such higher pressures. It is highly advantageous to place the more sensitive active components, such as clocks, sensors, antennas, and capacitors, in positions on surface 20 that are away from or far from the gates.

[0076] Once the form layer 22 is formed between the two elements 14, 18, the control unit 10 assumes its final form, comprising the first element 14, which defines the A-surface 16 with graphic features with which the user can interact; the second element 18, which defines the B-surface 20, which carries the various electronic components that are controlled by the user's interactions with the A-surface 16; and the form layer 22 between the first and second elements to give the unit stability and structure.

[0077] The Fig. are schematic representations of two possible configurations for the control unit 10 that can be formed using a single injection molding process in which the injection molding compound is introduced into the mold as previously described to form the mold layer 22 of the control unit 10.

[0078] In Fig. The graphics layer is located on the reserve side of surface A (which would be transparent to allow visibility of the graphics layer). A hard layer 50 is additionally applied to surface A 16 as a protective surface, since this is the surface exposed in the vehicle cabin and may be subject to scratches and impacts during use. In this example, the mold layer 22 is approximately 2-3 mm thick, making the overall structure relatively thin and light compared to known electronic control units. The active electronic components 30, 32, 34 and conductive prints or traces 38 are applied to surface B 20 on the back of the structure as previously described. Fig. The configuration shown can be formed using a single-shot injection molding process to create the mold layer 22.

[0079] Furthermore, a piezoelectric layer (not shown) can be placed directly beneath the first element 14 (i.e., in close contact with or very close proximity to the first element 14). The piezoelectric layer is a pressure-sensitive layer through which the underlying electronic components 30, 32, 34 are controlled by the user by applying pressure to the surface of the first element 14, thus providing a piezoelectric control function for the underlying electronic components 30, 32, 34.

[0080] In further embodiments (not shown), electrode and dielectric layers can be provided in the layer structure of the control unit 10 to provide capacitive touch functionality for the unit. The electrode layer and the dielectric layers can be provided by the conductor tracks (e.g., 38). In this configuration, a small voltage is applied to the conductor tracks of the second element 18, resulting in a uniform electrostatic field. When a conductor, such as a human finger, touches the surface of the first element 14, a capacitor is dynamically formed with the conductor tracks. A basic controller printed on the second element 18 can then indirectly determine the position of the user's touch from the change in capacitance caused by the touch. This, in turn, can be used to control the underlying electronic components 30, 32, 34.The three-dimensional grooves 26, 40 and the sliding function provided by a user who pushes his finger through the groove 26 of the first element 14 can be realized by means of a piezoelectric or capacitive touch function.

[0081] In practice, the capacitive touch effect can be enhanced by integrating a base plate into the structure on the back of the second element 18 (i.e., on the opposite side of the mold layer 22).

[0082] In capacitive touch designs, no close contact between an electrode layer and the first element 14 is required as in a piezoelectric activation, since the change in capacitance through touch is sufficient to indicate the control.

[0083] Many more layers can be integrated into the structure to provide touch-sensitive or other user operation functions of the control unit 10, including resistive layers, piezoelectric layers, electromagnetic layers, QTC (Quantum Tunnelling Composite) layers, E-field layers and RF layers.

[0084] Fig. This is an alternative embodiment of the control unit in which the need for the second element of the structure is avoided and the electronic components 30, 32, 34 and conductive prints or traces 38 are formed on the reserve side of the first element 14 (i.e., the surface on the back side of the one with which the user interacts). In this case, the control unit is assembled by first applying the graphic features 24 to the back side of the first element 14 and then applying a hard layer 50 to the front side of the first element 14 to form the protective layer. The electronic components and traces 38 are then applied to the back side of the first element 14, and the assembly is placed in a mold. The injection molding material (e.g.,Polycarbonate is introduced into the mold to create the injection-molded layer on the back of the first element 14, encapsulating the electronic components 30, 32, 34 and conductive traces 38. The control unit structure in . Fig. can also be formed using a single injection molding process to create the mold layer 22, as in Fig. .

[0085] The Fig. show alternative embodiments that can be formed using the twin-shot (2K) injection molding process. Fig. resembles the embodiment of Fig. The electronic components 30, 32, 34 and the conductive traces 38 are mounted on the second element 18 and spaced from the front surface of the control unit by the mold layer 22. In this embodiment, however, the first element is no longer necessary. Instead, the graphic features 24 are placed in a mold and the second element 18 in a planar mold. A first shot of injection molding material is then injected into the gates 44 to fill the cavity between the molds; the material is cooled and sets. Using a second mold, the hard layer 50 is then formed on the front face of the structure with a second injection of injection molding material (i.e., the hard layer is applied directly to the mold layer 22).

[0086] Fig. Another alternative embodiment uses a second shot of injection molding material to create enhanced depth effects on the front of the control unit 10. In this embodiment, only one element 14 is required to support the electronic components 30, 32, 34 and the conductive traces 38. These components and conductive traces are applied directly behind the graphic features 24, which are applied to the back of the first element 14, as shown in Fig. As described, a first shot of injection molding material is applied to a mold to encapsulate the back of the first element 14, along with the electronic components 30, 32, 34 and the graphic features 24. A second shot of injection molding material is then injected into a pre-mold to encapsulate the front of the first element 14 and define a relatively thick and transparent front layer 52. The depth of the transparent layer 52 on the front of the structure can be used to achieve enhanced depth effects for the graphic features 24 on the back of the first element 14. For example, the transparent layer can be provided with various cutouts or holes of different shapes and depths to achieve different lighting effects from the LEDs 30, 32, 34.

[0087] In further embodiments (not shown), the hard protective coating 50 applied to the front of the first element 14 can be in the form of a veneer, such as a wood-effect veneer, which matches or complements the cladding of the vehicle cabin in which the control unit 10 is to be used.

[0088] This allows the control unit to be easily placed in a highly visible location within the vehicle cabin and, thanks to its aesthetically pleasing surface, can be integrated into an armrest, a ceiling panel, or the dashboard, for example. The veneer can be in the form of any thin layer of suitable material such as wood, carbon fiber, shrink-wrap polymer, metal, textile, or leather.

[0089] Fig. This is another alternative embodiment of the invention, in which both the first and the second elements 14, 18 are provided with electronic components, characterized as 30, and the necessary conductor tracks 38. As already mentioned, the first element 14 can be provided with a protective layer 50, although this is not strictly necessary. This embodiment can be particularly useful for a control unit configured for gesture control, wherein the electronic components must be arranged near surface A of the control unit, while other electronic components can be arranged on surface B of the control unit.For example, the surface area of ​​the control unit may not be sufficient to accommodate all the necessary electronic components, or it may be advantageous to distribute the electronic components in order to minimize, for example, the local heat generation of the components used.

[0090] The in Fig. The illustrated embodiment can be provided with a connector (not shown) configured to apply the required currents to the electronic components. It may be desirable to control the electronic components on each of the elements 14, 18 via a common connector, rather than using individual connectors for each one.

[0091] Fig. Figure 1 shows another alternative embodiment in which the encapsulation of the printed electronic components by the form layer 22' only partially occurs over a surface of the structure. This can be advantageous, for example, if the installation space for the control unit is particularly limited and the unit can be partially housed in an already enclosed and secure environment without requiring additional encapsulation over the entire printed electronic layer.

[0092] Due to the high temperatures and pressures of the aforementioned injection molding process, and despite the careful positioning of the gates away from the most sensitive electronic components, damage to conductive elements or traces can occur when the injected material enters the mold cavity through the gates. Therefore, it may be advantageous to place active electronic components outside the gates and passive electronic components near the gates, as the passive components are less susceptible to damage.

[0093] Furthermore, some electronic components require a higher current for power (e.g., higher-power LEDs), so it is advantageous to allow redundancy of these conductor tracks to ensure that even in the event of a break or damage during the injection molding process, sufficient current can be supplied via the remaining conductor tracks to the components that are not broken or damaged.

[0094] For the reasons described above, the selection criterion for the location of certain components may be to place active electronic components outside the gates and passive components near the gates. Another criterion may be whether a component is critical for the desired function of the control unit 10. If a component is considered critical for the operation of a control unit (e.g., an LED that illuminates a control unit for a display), then it is advantageous to place the critical component outside the gate area, thus minimizing the probability of damage to the traces supplying power to the LED and / or the LED itself. It is also advantageous to place the more delicate copper traces of surface B further away from the gates, while the silver traces may be more robust against the high-pressure flows through the gates during injection molding.

[0095] Since the control unit is flexible during assembly, some deflection of the conductor tracks to the electronic components can occur during manufacturing before the injection-molded material sets. Even in embodiments where the control unit retains some flexibility after manufacturing, the risk of damage to the conductor tracks during use of the control unit remains. To counteract any potential damage, it can be advantageous to provide an excess of conductive prints or traces to ensure some redundancy for the conductor tracks in the event of such damage. In particular, redundant conductor tracks 38 can be provided in the areas in front of the gate(s) 44, which are most susceptible to damage due to the highest pressure.This track redundancy ensures that even in the event of a break, a suitable number of tracks are maintained, so that the specific current requirements for the electronic components and the impedance at the connection point between the electronic component and the conductor tracks are met as required.

[0096] Another problem that can occur is that the cooling and curing process, which follows the high temperatures and pressures of the injection molding process, can lead to shrinkage and breakage of the conductor tracks 38 due to deformation of the underlying layer or the substrate onto which they are applied. Therefore, care must be taken when selecting a suitable ink viscosity and conductor track density for the conductor tracks 38. The size and density of the tracks depend not only on their positioning relative to the gates but also on the electrical load requirements of the components to which the tracks are connected.

[0097] As described below, other methods for manufacturing the control unit of the invention can be used to completely avoid the problems mentioned above.

[0098] To provide additional protection for the more thermally sensitive electronic components, it can be advantageous to integrate a heat sink assembly into the control unit to dissipate the heat generated during the injection molding process away from these sensitive components. Providing a heat sink assembly also offers advantages during the operation of the control unit, as it allows the heat generated during operation to be dissipated from areas of the control unit that could be damaged or malfunction if overheated.

[0099] Fig. shows an embodiment of the control unit 10, which corresponds to the embodiment in Fig. It is similar in that it includes a first element 14, which defines an A-surface 16 of the control unit, such as a presentation area for the user with which the user interacts visually, and a second element 18, which defines a B-surface 20 on which various electronic components 60, 62 are mounted. In the example shown, the B-surface is equipped with three electronic components 60 that are sensitive to overheating and one component 62 that is less sensitive to overheating. Conductive traces (not identified), as previously described, are also provided on the second element 18 to supply power to the electronic components 60, 62.

[0100] A heat transfer arrangement, which can be referred to as a heat sink arrangement or thermally conductive layer 70, is incorporated in the control unit. The heat transfer arrangement takes the form of a thermally conductive layer designed to contact the three heat-sensitive electronic components 60. The thermally conductive layer 70 comprises a main body region 70a, which overlaps and thus comes into contact with the electronic components 60, and a contact region defined by an extension region 70b that projects from one end of the main body region 70a to make contact with one end of the second element 18. The heat accumulating in the electronic components 60 is transferred via the thermally conductive layer 70 to the second element 18, thus dissipating heat from the components 60 by thermal conduction.If one of the electronic components is less susceptible to high temperatures, such as the component marked 62, the thermally conductive layer 70 does not need to extend to this component, as shown in . Fig. The thermally conductive layer 70 can also include an additional layer 71, which adjoins the second element 18 and to which the electronic components 60 are thermally connected to ensure improved heat transfer. This is because the additional layer 71 provides another path for heat transfer from the electronic components 60 to the second element 18.

[0101] Heat is dissipated from the electronic components 60 via the thermally conductive layer 70 during the injection molding process at particularly high temperatures around the components, but also during operation of the control unit 10, when the electronic components can also heat up. The provision of the thermally conductive layer heat sink is therefore advantageous both during the manufacture of the control unit and during its use.

[0102] The material of the thermally conductive layer can be graphene or a metamaterial with high thermal and low electrical conductivity. For example, the layer can be made of phyllosilicates or a mica sheet. Other suitable materials are insulators (low electrical conductivity) in which atomic vibrations (phonons) make heat transfer very efficient. Materials with light elements (especially B, C, N, O) often exhibit high phonon thermal conductivity because the heat is usually transported by acoustic phonons whose group velocity (the speed of sound in the material) is inversely proportional to the atomic mass. Examples of materials with high thermal conductivity and low electrical conductivity include certain metamaterials and polymorphs of boron nitride, silicon carbide, silicon nitride, and aluminum nitride.

[0103] Fig. Figure 1 shows an alternative embodiment of the control unit 10 provided with a heat transfer arrangement. In this embodiment, the electronic components 60 are located on the back side of the first element 14 (i.e., on the surface opposite the A-surface 16), and the second element 18 serves as structural support for the control unit 10. As already described for the embodiment in Figure 1, Fig. As described, a main body region 70a of a thermally conductive layer 70 is superimposed on the three electronic components 60, which are most susceptible to damage or malfunction in the event of overheating. An extension region 70b of the thermally conductive layer 70 projects essentially perpendicularly from the main body region 70a to intercept the second element 18 on the rear side of the control unit 10. As before, heat is transferred from the electronic components 60 to the second element 18 via the thermally conductive layer 70 to protect the components from damage and / or malfunction due to overheating during manufacturing or operation.

[0104] Another alternative embodiment (not shown) uses a heat transfer device that is not as described in the Fig. It is not part of the final control unit structure, but rather part of the manufacturing tool used for the injection molding process. Therefore, the electronic components are only protected from heat during manufacturing.

[0105] In a further embodiment (not shown), in which a heat sink arrangement is used, a Peltier heat pump or a loop heat pipe can be used in combination with the heat-conducting element to enable active control of the heating or cooling of the encapsulated electronic circuit.

[0106] In further embodiments, it is provided that the heat-conducting heat transfer arrangement can be configured to, for example, conduct heat to the electronic components of the printed electronic circuit, without restriction if other features of the control unit require heat transfer from them.

[0107] Fig. Figure 1 shows a further embodiment of the invention in which the arrangement of layers 14, 18, 22, 71 is the same as in the embodiment in Figure 2. Fig. except that each layer is not flat, but follows a curved or wavy profile. The curved or wavy nature of the control unit is achieved by utilizing the pliability or flexibility of the layers during assembly to achieve the desired profile for the final product. This allows the control unit to take on a variety of shapes and be used in a wide range of applications. For example, within a vehicle, the control unit can be used as a lid for a glove compartment (as in...). Fig. (as shown) or used as an armrest in the vehicle, or it can be shaped or molded to define another surface of the vehicle interior where it may be useful to provide control functionality within a component that has a different purpose.

[0108] From the foregoing description, it should be emphasized that the invention offers a robust, lightweight structure for the control unit, which is located in a vehicle cabin and is visible to the user due to the high-quality and versatile processing on the A-surface 16 with which the user interacts. The shape of the control unit is very versatile due to the flexibility of the structure, at least during assembly. One such embodiment is the one described above and in the Fig. The overhead control panel shown is one example. Other applications for the control unit include an armrest control panel for controlling the vehicle windows or door locks, a center console control panel for controlling the vehicle's entertainment system, or as a glove compartment lid, providing the user with a presentation area on the otherwise unused surface of the glove compartment lid.

[0109] In another embodiment (not shown), the control unit forms part of a vehicle sun visor. Typically, a vehicle sun visor is in the form of a flap that, in its lowered configuration, covers an area of ​​the windshield to reduce glare for the user, but can be stowed in an upper, essentially horizontal configuration that rests against the top of the windshield frame when not in use. Conventional sun visors are often equipped with a vanity mirror and a light source that illuminates the area around the mirror and the user's face when the visor is lowered. The light source is either operated by a switch on the sun visor or illuminates automatically when the visor is lowered.In the present invention, the control unit can be mounted on the sun visor, allowing the electronic components (whether mounted on the back of surface A or on surface B) to be conveniently packaged within the sun visor unit, thus ensuring improved lighting functionality. For example, the illumination level of the light source can be controlled depending on the ambient light level, or the timing of illumination by the light source can be adjusted depending on other vehicle parameters or operating modes. The invention therefore makes it possible to provide an integrated light-emitting system within the small space of a vehicle sun visor to achieve improved lighting characteristics.

[0110] In other embodiments of the invention, when used in a vehicle, the invention can take the form of a display panel that presents information to the user instead of providing an interaction surface. For example, the control unit can be configured to control a hidden, illuminated function of the vehicle, where the illumination of the function by a light source (e.g., LED) in the control panel highlights the function for the user, which would otherwise not be visible.

[0111] In one of the aforementioned embodiments, the materials and / or the thickness of the various layers can be selected such that the finished control unit retains a certain degree of flexibility or reliability. It is important that the layers exhibit a certain degree of flexibility during manufacturing so that the final control unit can be shaped as desired during the assembly process. It may be advantageous for the control unit to assume a rigid structure in its final form (e.g., due to the first and second elements and the injection-molded layer 22, which is rigid once cured), but in other embodiments, it may be advantageous for the first and second elements and the injection-molded layer to retain a certain degree of flexibility, e.g., to allow the control unit to be bent during use.For example, flexibility can improve user interaction by providing a flexible, interactive, and touchable interface.

[0112] The embodiments of the invention described above are used in injection molding to produce the intermediate layer of the control unit (as in the Fig. ) and / or the encapsulation layer(s) (as in the Fig. ). To avoid the problems associated with the high temperatures and pressures of the injection molding process, the control unit structure can alternatively be formed by a lamination process to replace the injection molded layer with a laminate layer. Fig. Figure 1 is a schematic diagram illustrating a control unit 110 formed from laminate layers. As already described, the first element 114 defines an A-surface 116, which provides the user with graphical features as indicators for controlling the unit. The second element 118 defines a B-surface 120, which carries the various electronic components and conductor tracks (not shown in Figure 1). Fig. (shown). The third element 122, which is located between the first and second elements 114, 118, takes the form of a laminating layer such as an adhesive layer.

[0113] To assemble the control unit 110 using the lamination process, the first element 114 is pre-formed using the deep-drawing process as described previously and placed in a mold. The second element 118 is formed using a similar process as described previously and placed in a flat mold. The adhesive layer 122 is then applied to the first or second element. The adhesive layer is preheated to be flexible but is made of a material that does not require excessive preheating to achieve the necessary flexibility.

[0114] Once the adhesive layer 122 is applied to the first or second element 114, 118, the molded parts are brought together to exert pressure on them, clamping the adhesive layer 122 between the first and second element 114, 118. Heat is then applied to the structure, causing the adhesive to conform precisely to the shape of the first and second element 114, 118 and bond the parts together. The presence of the adhesive on the second element 118 is advantageous because it forms a protective layer for the electronic components and circuits during the heating phase. Furthermore, the phase change of the adhesive layer during heating dissipates energy from the components and circuits.Finally, the assembled structure is cooled so that the adhesive hardens to securely join the first and second elements 114, 118 together in a rigid structure, with the adhesive forming a mold layer 122 between them.

[0115] In a further embodiment (not shown), in which a laminate adhesive layer is used to hold the control unit elements together, the need for two base elements 114, 118 can be eliminated if the graphic elements are placed directly into a mold instead of being applied to a first element 114. The adhesive is then applied directly into the mold onto the graphic features and sandwiched together with the second element 118 to form a two-layer structure, with the graphic features being embedded or embossed on the surface of the adhesive layer.

[0116] In a further embodiment (not shown), the control unit can comprise two or three layers formed by a lamination process, so that the layer onto which the electronic components and conductor tracks are printed is a flexible film or layer instead of a rigid preform.

[0117] One advantage of the adhesive lamination process is that it avoids the high temperatures and pressures required for injection molding. Furthermore, it eliminates the need to incorporate gates within the first and / or second elements 114, 118, as the adhesive is applied simply and flexibly to one of the layers. The lamination process also allows for the stacking of integrated circuit components onto the B surface (or the back of the A surface), which would otherwise be inaccessible due to the high temperatures and pressures of injection molding, which would too easily deform the stacked circuits. Suitable materials for the lamination process include resins, vinyls, and ethylene copolymer resins.

[0118] Further embodiments provide for a hybrid arrangement of a laminated control unit structure in a part of the vehicle, integrated in a common arrangement with a molded control unit structure. For example, the vehicle's armrest can include a molded high-gloss unit with a wood-effect veneer containing the control functions of surface A, with the laminated unit adjacent to it forming the support surface for the arm.

[0119] Fig. Figure 1 shows a possible configuration of the second element 118, which can be used to form part of the control unit 10 in one embodiment, wherein the control unit 10 takes the form of a display unit. The control unit can be used with an injection-molded mold layer 22 or a laminated encapsulation layer 122. The in Fig. The configuration shown is a laminated structure formed by applying various materials and electronic components to a base layer (backlight layer 73) to achieve the desired lighting function.

[0120] The printed electronics are applied to the backlight layer 73, which provides a supporting structure to the second element 118 and serves as a source of backlighting for the components located on it. A first polarization layer 72 is then applied to the backlight layer 73, and a series of liquid crystal display (LCD) elements 74 are then applied to the first polarization layer 72. The LCD elements 74 can be deposited in the form of an ink and are interspersed with structural supports or pads 76, with a support 76 located between adjacent LCD elements. A transistor layer 78 is applied to the LCD elements 74, forming the switching layer for the LCD elements. Voltages are applied to the transistors to control the LCD elements as desired, under the control of a microprocessor (not shown).A series of color filter elements 80, typically RGB filter elements, are applied to the transistor layer 78. The color filter elements 80 are interspersed with further structural supports 82, as in the LCD elements 74. The structural supports 76, 82 can be formed from the same material and can, in fact, be integral supports that extend through each layer of the structure 118. Before applying an antireflective coating 86, such as glass or acrylic, a second polarizing layer 84 is then applied to the color filter elements 80 to provide the second element 18 with a suitable surface finish. A heat sink arrangement 88 in the form of a thermally conductive layer, as described above, can also be incorporated into the laminated structure.

[0121] The LCD elements 74, interspersed with the structural support elements 76, can be formed using a conventional inkjet or 3D printing process. For example, the 3D arrangement of printheads used to form the LCD elements 74 can include a first liquid crystal material in selected printheads and a second, different material in other printheads to obtain a regular arrangement of LCD elements with structural supports positioned at regular intervals between them. Typically, the second material from which the structural supports 76 are formed is a curable resin that can be cured, for example, by UV radiation. It can be advantageous for the resin to be a transparent material so that the structures are not visible in the final product.If the final display unit 10 is to exhibit a certain degree of flexibility, the supports 76 can be made of silicon to provide both support and the necessary flexibility. In this case, the shape of each support 76 is chosen such that the supports 76 exhibit the required robustness even when the final structure is bent. In particular, the shape of the supports 76 is chosen such that the pressure exerted on the supports is distributed evenly across them, even when the assembly is bent. For example, the supports can be designed in the form of V-shaped structures or columns with an oval or circular cross-section, which retain their ability to provide support even when bent.

[0122] In other embodiments, various materials with different properties can be deposited to form the printed electronic layer. For example, inks with conductive, resistive, and semiconducting properties can be deposited on the component-bearing surface to form the printed electronic circuit, depending on the required functionality.

[0123] Fig. shows the arrangement of the support elements 76, which were formed using a 3D printing process as described above, while in Fig. The structural support elements 76 were formed using a screen printing process. The supports 76 can comprise a softer, more flexible material for flexible displays (such as silicone) or a harder, stiffer material (such as melamine) for rigid displays.

[0124] The LCD elements 74 are operated in a manner known in the art by applying a voltage to the transistor layer 78 to control the switching of the liquid crystal molecules in each element, which in turn determines whether the light passing through the first polarization layer 72 is passed through or blocked by the LCD elements 74.

[0125] In another embodiment (not shown), the structural support elements 76 can be formed within the second element 118 by first applying a layer of resin to, for example, the arrangement of the LCD elements 74 and then etching away the resin so that it does not obstruct the light transmission through the structure when the LCD elements are activated for light transmission, but leaves an arrangement of structural supports spaced at appropriate intervals to provide mechanical strength to the second element 118.

[0126] The embodiment in the Fig. , Fig. until Fig. The invention describes a liquid crystal display, but other types of displays can also be used, such as LEDs, OLEDs, AMOLEDs, quantum dot displays, electrophoretic displays, and electrowetting displays. The display elements can be formed by using different inks to print on various components, such as those mentioned above.

[0127] When the injection molding process is used to form the entire control unit structure, the in Fig.The illustrated configuration of the second element 18 is particularly advantageous because it provides the second element 18 with additional rigidity through the use of a series of mechanically stable supports or columns 76 distributed across the entire printed electronic layer. This rigidity withstands the high temperatures and, in particular, the pressures that occur during the injection molding process. Despite the rigidity of the supports or columns 76, the overall structure can still exhibit a degree of flexibility or ductility in its final shape, allowing its form to be adapted to the application requirements, as previously explained.

[0128] It should be noted that many modifications to the above examples can be made without altering the scope of the invention as defined in the accompanying claims. For example, although embodiments of the invention have been described with reference to a control unit for a vehicle, it should be noted that the invention has other applications outside the automotive sector. Alternatively, the invention can be used, for example, in a variety of devices where a user interaction surface and / or a surface on which information is displayed to a user is required (e.g., a control panel on an electrical device). In this sense, the A-surface of the control unit in none of the aforementioned embodiments need it be in the form of a surface with which the user interacts, but can take the form of a surface on which information is displayed or presented to the user of the control unit.

Claims

[1] A control unit (10) for a device, wherein the control unit (10) comprises: a component-supporting element (14) provided with at least one electronic component (30, 32, 34) configured to provide a function of the device; wherein the component-supporting element (14) is formed from a material that is flexible at least during the assembly of the control unit; a second element (18) that defines a user interaction area visible to a user of the device in use; an injection-molded mold layer (22) that encapsulates at least part of the electronic component or each component (30, 32, 34); wherein the second element (18) is provided with at least one further electronic component (30, 32, 34), such that the electronic component(s) (30, 32, 34) or each of the electronic components (30, 32, 34) are located on the component-supporting element (14) and the at least one further electronic component (30, 32, 34) on the second element (18) are arranged between the component-supporting element (14) and the second element (18) within the injection-molded mold layer (22); and wherein the user interaction surface is configured to receive a user command, and wherein the electronic component or components (30, 32, 34) are functional in response to the user command, the control unit (10) further features: a piezoelectric layer adjacent to the user interaction surface to enable control of the electronic component (30, 32, 34) when the user applies a user command in the form of pressure to the user interaction surface. [2] Control unit (10) according to claim 1, wherein the component-supporting element (14) remains malleable after the complete assembly of the control unit. [3] Control unit (10) as claimed in a previous claim, wherein the second element (18) is spaced apart from the component-supporting element (14) by the injection-molded mold layer (22) to define at least a three-layer structure for the control unit (10). [4] The control unit (10) as claimed in a previous claim, comprising a component-supporting surface which supports the electronic component or each electronic component (30, 32, 34) and wherein the component-supporting surface is located on the back side of the component-supporting element (14) facing the user interaction surface. [5] The control unit (10) as claimed in a previous claim, wherein the or each electronic component (30, 32, 34) forms part of a printed electronic circuit comprising a plurality of conductors (38) to conduct current to the at least one electronic component. [6] Control unit (10) according to claim 5, wherein the conductor tracks (38) together with the user interaction surface act as electrodes of a capacitor to provide a capacitive touch control function in response to the user command. [7] Control unit (10) according to claim 5 or claim 6, wherein a larger number of conductor tracks (38) are provided on the printed electronic circuit than is required to supply sufficient current to the at least one electronic component (30, 32, 34) of the printed electronic circuit and thereby ensure trace redundancy in the event of breakage and / or failure of one or more of the conductor tracks (38). [8] Control unit (10) according to claim 7, wherein a larger number of conductor tracks (38) are provided on the printed electronic circuit in areas near a gate (44) for injecting a material of the mold layer (22) during the assembly of the control unit (10). [9] The control unit (10) as claimed in a previous claim comprising an additional layer (71) provided on the user interaction surface to give the control unit (10) an aesthetic finish. [10] Control unit (10) according to claim 9, wherein the additional layer (71) is a veneer that complements a surface of the device in which the control unit (10) is used. [11] Control unit (10) according to claim 9 or claim 10, wherein the additional layer (71) is a protective layer (50). [12] The control unit (10) according to any one of claims 9 to 11, wherein the additional layer (71) is a further injection-molded layer. [13] Control unit (10) according to one of claims 9 to 12, wherein the additional layer (71) is provided with one or more recesses. [14] The control unit (10) as claimed in a previous claim, wherein the user interaction surface is provided with at least one graphic feature (24) to give the user a display about at least one function of the electronic component. [15] The control unit (10) as claimed in a previous claim, comprising at least one active electronic component (30, 32, 34). [16] The control unit (10) as claimed in a previous claim comprising at least one passive electronic component. [17] Control unit (10) according to claim 15 or claim 16, wherein the active electronic component (30, 32, 34) is located remotely from the passive electronic component on the component carrier. [18] The control unit (10) as claimed in a previous claim, comprising at least one gate (44) through which the material of the mold layer (22) is injected during the manufacture of the control unit (10). [19] The control unit (10) according to claim 18, when it is dependent on any one of claims 15 to 17, wherein the at least one active electronic component (30, 32, 34) is arranged remotely or spaced apart from the at least one gate (44). [20] The control unit (10) according to any one of claims 1 to 18, configured for use in a vehicle (12, 100). [21] The control unit (10) according to claim 20, wherein the at least one electronic component (30, 32, 34) is configured to control one or more of the following vehicle functions: an airbag, an entertainment system, a sound system, a window, a seating system, a lighting system. [22] Control unit (10) according to any one of claims 1 to 21, wherein the control unit (10) has a curved, wave-like or non-planar shape. [23] Device comprising the control unit (10) as required in any one of claims 1 to 22. [24] The device according to claim 23 in the form of a vehicle (12, 100). [25] Method for manufacturing a control unit (10) for a device, comprising the method; Preforming of a component-bearing element (14) in a first preforming step; Preforming a second element (18) in a second preforming step, wherein the second element (18) defines a user interaction surface that is visible to a user of the device in use; Providing at least one electronic component (30, 32, 34) on the component-supporting element (14) to provide a function of the device used; Providing at least one further electronic component (30, 32, 34) on the second element (18); and Injecting an injectable material onto the at least one electronic component to encapsulate the at least one electronic component at least partially in an injection-molded mold layer (22), such that the electronic component(s) on the component-supporting element (14) and the at least one further electronic component on the second element (18) are sandwich-like arranged between the component-supporting element (14) and the second element (18) within the injection-molded mold layer (22). [26] The method according to claim 25, comprising: after the first and second preforming steps, injecting the injection molding material between the component-supporting element (14) and the second element (18) in order to at least partially encapsulate the at least one electronic component and to define at least one three-part structure for the control unit (10). [27] Method according to claim 25 or claim 26, wherein the preforming step of the component-supporting element (14) in the first preforming step comprises injection molding of the component-supporting element (14).

Images