Control unit, device with control unit and assembly method

Abstract

Control unit (10) for a device (12), wherein the control unit (10) comprises: a component-supporting element (14; 18) provided with at least one electronic component (30, 32, 34, 36, 38; 60, 62, 73, 74, 78) configured to provide a function of the device (12); wherein the component-supporting element (14; 18) is formed from a material that is malleable at least during assembly of the control unit (10); a second element (18) that defines a user interaction interface (16) visible to a user of the device (12) during use; an encapsulation layer (22, 122) made of laminate, which encapsulates at least one part of the electronic component or components (30, 32, 34, 36, 38; 60, 62; 73, 74, 78); wherein the second element (18) is provided with at least one further electronic component, such that the electronic component or components (30, 32, 34, 36, 38; 60, 62; 73, 74, 78) are located on the component-supporting element (14; 18) and the at least one further electronic component on the second element (18) are arranged between the component-supporting element (14; 18) and the second element (18) within the encapsulation layer (22, 122) made of laminate; and wherein the user interaction interface (16) is designed to receive a user command, and wherein the electronic component or components (30, 32, 34, 36, 38; 60, 62; 73, 74, 78) are operable in response to the user command, the control unit (10) further comprises: a piezoelectric layer adjacent to the user interaction surface (16) to enable control of the electronic component(s) (30, 32, 34, 36, 38; 60, 62; 73, 74, 78) when the user applies the user command in the form of pressure on the user interaction surface (16).

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 comprising electronic components and / or microprocessors for operating the device. The control unit can be used, in particular, but not exclusively, in a vehicle. Aspects of the invention relate to a control unit, a device, and an assembly method. BACKGROUND

[0002] Modern motor vehicles have numerous different systems and subsystems that require electronic control units (ECUs) to function and be controlled. Examples of the necessary control units include the various airbags distributed throughout the vehicle cabin, interior lights, front and rear seats, the entertainment module and / or DVD player, parking assistance systems, various motion and other sensors, the power steering, and the off-road and navigation systems, to name just a few. Additional electronic control units are also required 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 have 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] In this context, US 7,091,886 B2 relates to a flexible touch switch comprising a force-sensitive composite material and at least one proximity sensor. Furthermore, WO 2006 / 048,627 A1 relates to an improved switching panel (SP), for example, for use in motor vehicles or electronic / electrical devices such as household appliances or keyboards. Finally, US 2016 / 0192,499 A1 relates to a manufacturing process for an electronic device comprising the following steps: A printed circuit board (PCB) and at least one electronic component are provided, the electronic component being mounted on the PCB. A protective cover is placed on the PCB to enclose the electronic components. A housing is formed by inset injection molding to enclose the PCB and the protective cover.

[0005] A particular challenge with existing control units is the limitation of their shape and size, which restricts their placement. 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 units makes it difficult to install them in confined spaces.

[0006] The present invention was developed to mitigate or overcome at least some of the problems mentioned above. SUMMARY OF THE INVENTION

[0007] Aspects and embodiments of the invention provide a control unit for a device, a apparatus, a manufacturing process and a vehicle, as required in the attached claims.

[0008] 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 encapsulation layer of laminate that encapsulates at least a part of one or each electronic component.

[0009] 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.

[0010] Since the component-supporting element is made of a material that is pliable or flexible, at least during the assembly phase of the control unit, a further advantage of the invention is that the component-supporting element can be manipulated to assume a variety of different shapes and thus adapt to 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.

[0011] Furthermore, as part of the manufacturing process, since the encapsulation layer is formed from laminate over the component-bearing element, the layer and the element can be shaped together to define the required shape for the final product.

[0012] Depending on the material chosen for the component-supporting element, the application of the laminate encapsulation layer causes the two materials to fuse together, effectively embedding, fusing, or integrating the electronics into the structure's materials in the final product. In other words, the components appear to be "suspended" within the structure, formed between the laminate encapsulation layer and the component-supporting element. In some embodiments, the layered structure of the fully assembled control unit may no longer consist of separate layers at all.

[0013] In one embodiment, the component-supporting element can be formed from a material that is flexible during the assembly phases but "solidifies" or becomes more rigid after the control unit is assembled, thus defining a rigid end product. Alternatively, the material from which the electronics-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.

[0014] 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, at least during the manufacturing phase, it can, for example, be adapted to a shape that can be used as a glove compartment lid or for an overhead control panel, which generally have a curved surface.

[0015] 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.

[0016] Other embodiments provide that the control unit forms a panel of a household appliance, such as electrical appliances like washing machines, stoves or dishwashers and the like.

[0017] 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 in 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 laminate encapsulation layer, which encapsulates the fragile and sensitive electronic components and circuits. The user command can be pressing 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 switching on a light.

[0018] The control unit includes a user interaction interface that is visible to a user of the device in use.

[0019] In one embodiment, the component-supporting element defines the user interaction surface.

[0020] The user interaction interface can be designed in the form of a presentation interface visible to the user.

[0021] The user interaction interface is configured to receive a user command, whereby the component-bearing element is operable in response to the user command.

[0022] A piezoelectric layer is to be integrated 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 at least one electronic component.

[0023] The control unit can include a component-bearing surface that supports the electronic component or components that may be part of a printed electronic circuit.

[0024] For example, in one embodiment, the component-bearing surface can be located on the back of the circuit-supporting element facing the presentation surface. This embodiment offers the advantage that only a single element is required to define both the presentation surface 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 using a suitable lamination process to provide the laminate encapsulation layer.

[0025] The control unit can include a second element that is spaced apart from the component-bearing element by the encapsulation layer made of laminate to define a three-layer structure for the control unit.

[0026] The second element can define the presentation interface.

[0027] The load-bearing element and / or the second element can take the form of a pre-formed layer, i.e., a layer formed prior to the step of creating the encapsulation layer from laminate in the lamination process. The load-bearing element and / or the second element can also be laminate layers.

[0028] The three-part structure of the component-bearing element, the second element and the encapsulation layer made of laminate 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 each electronic component, is required.

[0029] In another example, the second element can be provided with at least one additional electronic component, such that the electronic component or components on the component-bearing element and the at least one additional electronic component on the second element are located between the component-bearing element and the second element within the injection molded layer.

[0030] This arrangement offers the advantage that the electronic components are distributed across different surfaces, which can be beneficial in terms of space and / or heat generation. The arrangement is particularly advantageous when the control unit is operated via gesture control, as the gesture-controlled components are located on the back of surface A, while other components can be moved from these and placed on the other element.

[0031] 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.

[0032] The conductive traces, together with the user interaction surface, can act as electrodes of a capacitor to provide capacitive touch control functionality in response to user commands.

[0033] The capacitive touch control offers the user of the control unit a fast, effective and sophisticated operating experience.

[0034] In one embodiment, a larger number of conductor tracks than required can be provided on the printed electronic circuit in order to supply electronic components of the printed electronic circuit with sufficient current and thus ensure trace redundancy in the event of breakage and / or failure of one or more conductor tracks.

[0035] The advantage of this track redundancy is that, for example, any track break or malfunction caused by damage during the manufacturing step of the laminate encapsulation layer is compensated for by providing additional tracks that still ensure the necessary current is applied to the electronic components used in the circuit. This is particularly advantageous because the injection molding process must be carried out at high temperatures.

[0036] The control unit may include an additional layer on the user interaction surface to aesthetically complete the control unit.

[0037] 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 if the control unit is a control unit for a vehicle. The intention of such additions is that the veneer matches or is otherwise complementary to 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.

[0038] The additional layer can be a protective layer.

[0039] For example, the additional layer could be an injection-molded layer or another laminate layer.

[0040] 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).

[0041] The control unit may include a thermally conductive element that is at least partially encapsulated in the laminate encapsulation layer and configured to conduct heat to or from the at least one electronic component.

[0042] The use of a thermally conductive element within the control unit offers several advantages. First, during the assembly of the control unit, the high temperatures associated with the lamination process, which can lead to heat buildup in the electronic components and otherwise damage the circuit, are dissipated away from the circuit, either to a remote component or to a component-supporting and / or secondary element, depending on where the thermally conductive element is located or thermally contacted. The remote component can, for example, be part of the tooling used in the lamination process, or alternatively, the thermally conductive layer can be in thermal contact with the component-supporting element and / or the secondary element, conducting heat across or to these elements.Secondly, during operation, as components of the electronic components and the circuit heat up during operation, the heat is conducted away from the circuit via the thermally conductive element.

[0043] In this way, unwanted heat energy from the electronic components can be used to warm 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 air conditioning system.

[0044] The load-bearing element and / or the second element may include a pre-formed element, i.e., an element formed before the laminate encapsulation layer is created. For example, the laminate encapsulation layer may be made of an adhesive or other material that is flexible when heated and becomes less flexible or solidifies upon cooling.

[0045] The component-supporting element can be provided with a multitude of structural supports to increase the rigidity of the control unit. In one embodiment, the printed electronic circuit can comprise a multitude of electronic components, with the structural supports being distributed among the electronic components.

[0046] The use of structural supports gives the control unit a certain stiffness, which can be particularly useful if the component-bearing element is a relatively thin layer or a laminated substrate.

[0047] 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.

[0048] 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.

[0049] The device can, for example, be designed in the form of a vehicle.

[0050] 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 component-supporting element in a first preforming step; providing at least one electronic component on the component-supporting element to provide a function of the device in use; placing a flexible laminate layer on the at least one electronic component and optionally cooling or setting the flexible laminate layer to thereby form an encapsulation layer of laminate over at least a part of the at least one electronic component.

[0051] The process includes preforming a second element in a second preforming step and, after the first and second preforming steps, placing the flexible laminate layer between the component-bearing element and the second element to form the laminate encapsulation layer on the at least one electronic component, for example after cooling or curing.

[0052] The curing of the flexible laminate layer can be achieved, for example, by UV curing.

[0053] 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.

[0054] 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 description and drawings, and in particular their individual features, may be adopted independently of one another 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 so that it depends on another claim and / or incorporates a feature of another claim, even if it was not originally claimed in this manner. BRIEF DESCRIPTION OF THE DRAWINGS Fig. Figure 1 is a schematic diagram of a known vehicle, showing the positions of various electronic control units around the vehicle. One or more embodiments of the invention will now be described – merely by way of example – with reference to the corresponding drawings, in which: Fig. 2 is a side view of a vehicle in which embodiments of the invention can be used; Fig. Figure 3 is a perspective view of the vehicle interior from Fig. 2, to illustrate positions where the control unit of the embodiments of the invention can be used; Fig. 4 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. 2 and Fig. 3 types shown can be used; Fig. Figure 5 is a top view of a printed electronics layer that is part of the control unit. Fig. 4 is; Fig. Figure 6 is a schematic cross-section of the control unit in Fig. 4, which was manufactured using a single-stage injection molding process; Fig. Figure 7 is a schematic cross-section of a control unit of a second embodiment, which was also manufactured using a single-stage injection molding process; Fig. Figure 8 is a schematic cross-section of a control unit of a third embodiment, which was formed using a two-stage injection molding process; Fig. Figure 9 is a schematic cross-section of a control unit of a fourth embodiment, which was also manufactured using a single-stage injection molding process; Fig. Figure 10 is a schematic cross-section of a control unit of a fifth embodiment, which was formed in a single-stage injection molding process; Fig. Figure 11 is a perspective view of a control unit of a sixth embodiment with only partial encapsulation of the printed electronic layer; Fig. Figure 12 is a schematic cross-section of a control unit of a seventh embodiment, which includes a heat sink arrangement; Fig. Figure 13 is a schematic cross-section of a control unit of an eighth embodiment with a different heat sink arrangement than in Figure 13. Fig. 12 shown; Fig. Figure 14 is a schematic cross-section of a control unit of a ninth embodiment, in which the profile of the control unit is curved; Fig. Figure 15 is a schematic, perspective view of a control unit with a three-layer structure formed by a lamination process; Fig. Figure 16 is a schematic cross-section of a printed electronic layer that can be used in embodiments of the invention; Fig. Figure 17 is a perspective view of a section of the printed electronic layer in Fig. 16, to show a supporting structure of it; and Fig. Figure 18 is a perspective view of a section of a printed electronic layer in an alternative embodiment to that shown in Fig. Figure 17 is shown to represent an alternative support structure for the printed electronic layer. DETAILED DESCRIPTION

[0055] With reference to Fig. 1. The various functions within the vehicle cabin in a modern vehicle, together with the engine and the drivetrain, require that numerous control units (or controllers) are located in an already limited space within the vehicle. Fig. Figure 1 illustrates only some of the possible locations for the control units, some of which are marked with the reference number 10, which may be distributed throughout the vehicle 12. For example, it is not uncommon for a vehicle to be equipped with more than 70 such control units 10, including those for the cabin lighting systems, the airbags, the sunroof, the roof blinds, the windows, the front and rear seats, the parking sensors, various other sensor systems around the vehicle, and the in-vehicle entertainment system.

[0056] Fig. Figure 2 is a side view of a vehicle 100 in which embodiments of the invention can be used to offer advantages over known vehicles. The interior of the vehicle is shown in Fig. Figure 3 shows two possible positions for the control units of the invention. In one position, the control unit is configured as an overhead control unit 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 control unit associated with the glove compartment can control various vehicle functions, including, for example, lighting, seats, heating, audiovisual, and satellite navigation functions.

[0057] Fig. Figure 4 is an exploded view of a 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 within the confines of the vehicle cabin. The control unit 10 comprises three elements: a first element 14, which defines the user interaction interface for the user in the form of a presentation surface 16, visible to the user when the control unit 10 is installed in its operating location. The presentation surface can be referred to as the A-surface 16 of the unit.

[0058] 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 encapsulation layer made of laminate 22, which is arranged between the first and second elements 14, 18. Typically, in a vehicle, the "A-surface" is a surface that is presented to and / or with which a user interacts, for example, 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. 4 represented by separate elements 14, 18, which are separated from each other.

[0059] The following description shows that either the first or the second element can form the component-supporting 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.

[0060] The first and second elements 14, 18 are generally plate-shaped elements, but in other configurations they can be in the form of thinner layers or a single layer of material. The first and second elements 14, 18 are preformed elements that are pliable and flexible, at least during the assembly phases 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 lamination process to form layer 22.

[0061] With reference to Fig. 4. 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 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 other symbols.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 storage table, a seat control switch package, a glove box lid, or a part of the vehicle instrument panel.

[0062] Surface B 20 is defined by a second thermoformed element 18, which, at least during the manufacturing steps of the control unit 10, again assumes the form of a flexible element. The second element 18 is formed in the same way as the first element 14, and a variety of active and / or passive electronic components and printed traces or wires (generally denoted by 29) are applied to the second element 18 using known techniques. Typical passive components are 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 provided 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, engraving, offset printing, inkjet printing, aerosol deposition printing, or laser printing.

[0063] 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 create a whole 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 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.

[0064] In the present embodiment, the first and second elements 14, 18 are generally planar with a slight curvature on their upper surface. In other embodiments, the elements may, for example, be at least partially fully curved or rounded, determined by the shape of the available space they are 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.

[0065] In other embodiments of the invention, the first and second elements 14, 18 can be vacuum-formed elements, as opposed to thermoformed elements. Other preforming methods can also be used to produce the “preformed” elements 14, 18 before the encapsulation process with the intermediate layer 22 is carried out.

[0066] The materials selected for the first and second preformed elements 14, 18 can be materials that are bendable or foldable in the final state or have a stiffer structure depending on the application.

[0067] Fig. Figure 5 shows an example of a B-surface 20, which forms part of the second element 18 of the control unit 10. Fig. 4 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.

[0068] Surface B 20 is equipped with a printed electronic layer (29 - as in Fig. (as shown in Figure 4) is 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 figures but is not intended as a limitation.

[0069] 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. Figure 4 illustrates this. 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-to-illuminated functions, emergency call functions (E-call functions) or breakdown call functions (B-call functions), and LEDs to illuminate symbols or graphical features that provide the user with information on various functions of the control unit 10.

[0070] Surface B 20 is further equipped with a hybrid integrated circuit 36 ​​for controlling and operating the various electronic components 30, 32, 34. Conductive prints or traces (two of which are designated by 38) are printed onto different areas of surface B to supply power to the various components 30, 32, 34. In practice, for reasons that will be explained later, a larger number of traces can be provided than is required for each component 30, 32, 34. The 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 current 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.

[0071] 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.

[0072] Once the encapsulation layer 22 is formed between the two elements 14, 18, the control unit 10 takes on 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 encapsulation layer 22 between the first and second elements to give the unit stability and structure and to protect the electronic components.

[0073] The Fig. 6 and Fig. Figure 7 shows schematic views of two possible configurations for the control unit 10. Fig. 6 The graphic layer is located on the reserve side of surface A (which would be transparent to allow visibility of the graphic layer). A hard coating 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 encapsulation 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. It should be noted that the Fig. 6 and Fig. 7 are only schematic, so that the relative thicknesses of layers 14, 18, 22, as shown, are not necessarily representative of the layer thickness in a production version.

[0074] Furthermore, a piezoelectric layer (not shown) can be placed directly beneath the first element 14 (i.e., in close contact with or very close 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.

[0075] In other control units (not shown), electrode and dielectric layers can be provided in the layer structure of control unit 10 to provide capacitive touch functionality for the unit. The electrode and dielectric layers can be provided by the conductor tracks (such as 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. An underlying 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 “slider” function, which is 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.

[0076] 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 encapsulation layer 22).

[0077] In embodiments with capacitive contact, no close contact between an electrode layer and the first element 14 is required as in piezoelectric activation, since the change in capacitance through contact is sufficient to indicate the control.

[0078] Many more layers can be integrated into the structure to provide touch-sensitive or other user control functions of the control unit 10, including resistive layers, piezoelectric layers, electromagnetic layers, QTC layers, E-field layers and RF layers.

[0079] Fig. 7 is an alternative control unit in which the need for a structure for the second element 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 built up by first applying the graphic features 24 to the back side of the first element 14 and then applying a hard coating 50 to the front side of the first element 14 to form the protective layer. The electronic components and conductive traces 38 are then applied to the back side of the first element 14, and the assembly is placed in a mold.As described in more detail below, the encapsulation material is introduced into the mold to create the encapsulation layer on the back of the first element 14, which encapsulates the electronic components 30, 32, 34 and conductor tracks 38.

[0080] The embodiment of Fig. 8 resembles Fig. 6 in that the electronic components 30, 32, 34 and the conductive prints 38 are mounted on the second element 18 and spaced from the front surface of the control unit by the encapsulation 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 mold facing it. The encapsulation material is placed in the mold onto the second element. In a second mold, the hard coating 50 is then formed on the end face of the structure using an injection molding material (i.e., the hard coating is applied directly onto the encapsulation layer 22) or another laminate layer.

[0081] Fig. 9 is an alternative control unit in which improved depth effects can be generated 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 in Figure 7, the back side of the first element 14 is enclosed by the encapsulation layer 22, along with the electronic components 30, 32, 34 and the graphic features 24. A relatively thick and transparent front layer 52 is then formed on the front side. The depth of the transparent front layer 52 of the structure can be used to achieve enhanced depth effects for the graphic features 24 on the back side 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.

[0082] In other control units (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, that matches or complements the trim of the vehicle cabin in which the control unit 10 is to be used. This allows the control unit to be easily placed in a highly visible location within the vehicle cabin and, due to its aesthetically pleasing surface, can be integrated, for example, into an armrest, a ceiling panel, or the dashboard. The veneer can be, for example, in the form of any thin layer of suitable material such as wood, carbon fiber, shrink-wrap polymer, metal, textile, or leather.

[0083] Fig. Figure 10 is a further 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 conductive traces 38. As already mentioned, the first element 14 can be provided with a protective coating 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 alternatively, it may be advantageous to spread out the distribution of the electronic components in order to minimize, for example, the local heat generation of the components used.

[0084] The in Fig. The embodiment shown in 10 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.

[0085] Fig. Figure 11 shows another control unit in which the encapsulation of the printed electronic components by the encapsulation layer 22' only partially occurs over a surface of the structure. This can be advantageous, for example, when the 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.

[0086] Since the control unit is flexible during assembly, some deflection of the conductive traces to the electronic components can occur during manufacturing before the injection-molded material is applied. Even in embodiments where the control unit retains some flexibility after manufacturing, the risk of damage to the conductive traces during use remains. To avoid damage that can occur during the assembly process, it can be advantageous to provide an excess of conductive prints or traces to ensure some redundancy in case of such damage. This ensures that even if some traces fail during assembly, sufficient current can still be supplied to the components of the printed electronic circuit.This trace redundancy ensures that even in the event of a break, a suitable number of traces 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.

[0087] To provide additional protection for the more thermally sensitive electronic components, it can be advantageous to integrate a heat sink arrangement into the control unit to dissipate the heat generated during the injection molding process away from the sensitive components. Providing a heat sink arrangement 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. Each of the control units described above can be provided with a heat sink function in the form of a thermally conductive element; embodiments of the invention in which a heat sink function is integrated are now described.

[0088] Fig. Figure 12 shows an embodiment of the control unit 10, which is the Fig. Figure 8 is similar in that it includes a first element 14, which defines an A-surface 16 of the control unit, such as a presentation surface 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.

[0089] A heat transfer arrangement, which can be referred to as a heat sink arrangement 70, is incorporated into 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 the electronic components 60 and thus establishes thermal contact, and a thermal 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. Figure 12 illustrates this. The heat sink arrangement 70 can also include an additional layer 71 next to the second element 18, to which the electronic components 60 are thermally connected, in order to ensure improved heat transfer. The improved heat transfer results from the fact that the additional layer 71 provides an alternative heat transfer path from the electronic components 60 to the second element 18. Heat dissipation from the electronic components 60 via the thermally conductive layer 70 occurs during the injection molding process at particularly high temperatures around the components; heat transfer also takes place during the operation of the control unit 10, during which the electronic components can also heat up. Therefore, providing the thermally conductive layered heat sink is advantageous both during the manufacture of the control unit and during its use.

[0090] 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.

[0091] Fig. Figure 13 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 Fig. As described in Figure 12, a main body region 70a of a thermally conductive layer 70 is superimposed on the three electronic components 60, since these three electronic components 60 are most susceptible to damage or malfunctions in the event of overheating. An extension region 70b of the layer 70 projects essentially perpendicularly from the main body region 70a to define the thermal contact area and to intercept the second element 18 on the rear side of the control unit 10. As before, the heat from the electronic components 60 is transferred via the layer 70 to the second element 18 to protect the components from damage and / or malfunction due to overheating during manufacturing or operation.

[0092] Another alternative embodiment (not shown) uses a heat transfer feature that is not as described in the Fig. 12 and Fig. 13. Part of the final control unit structure, but part of the manufacturing tool used for the injection molding process.

[0093] This means that the electronic components are only protected from heat during manufacturing.

[0094] In a further embodiment (not shown), using a heat sink arrangement, 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. A Peltier heat pump, or thermoelectric heat pump as it is sometimes called, is a fixed, active heat pump that transfers heat from one side of the device to the other, consuming electrical energy depending on the direction of current flow. The heat pump can be used for both heating and cooling. It can also be used as a temperature controller that either heats or cools.

[0095] In further embodiments, it is provided that the heat-conducting heat transfer arrangement can be configured to, for example, direct heat to the electronic components of the printed electronic circuit, without restriction if other features of the control unit require that the heat be transported away from them.

[0096] Fig. Figure 14 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 14. Fig. 12, except that each layer is not flat but follows a curved or wave-like profile. The curved or wave-like nature of the control unit is achieved by utilizing the suppleness or flexibility of the layers during assembly to achieve the desired profile for the final product. This allows the control unit to assume a variety of shapes and be used in a variety of applications. For example, within a vehicle, the control unit can be used as a lid for a glove compartment (as in Fig. 3 shown) or it can be used as an armrest in the vehicle, or it can be shaped or cast 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.

[0097] 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 where it is visible to the user due to the high-quality and versatile processing on surface A 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. 3 and Fig. Four overhead control panels are shown. 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, on which a presentation surface can be presented to the user on the otherwise unused surface of the glove compartment lid.

[0098] 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 pull-down 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 pulled down. 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 limited space of a vehicle sun visor to achieve improved lighting characteristics.

[0099] 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 interface. For example, the control unit can be configured to control a hidden-to-illuminated feature of the vehicle, with the illumination of the feature by a light source (e.g., an LED) on the control panel highlighting the feature for the user, as it would otherwise not be visible.

[0100] In one of the aforementioned embodiments, the materials and / or the thickness of the various layers can be selected such that the fully assembled 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 adopt a rigid structure in its final form (e.g., due to the first and second elements and the injection-molded layer 22, if it is rigid), but in other embodiments, it may be advantageous for the elements and the injection-molded layer to retain a certain degree of flexibility, e.g., to allow the control unit to be bent during operation.

[0101] The method by which the control unit 10 of one of the aforementioned embodiments can be formed is now described. As already described, the first element 14 defines an A-surface 16, which transmits graphical features to the user as indicators for controlling the device. The second element 18 defines a B-surface 20, which carries the various electronic components and conductor tracks (not shown in the diagram). Fig. 15 shown). The third element 22, which is located between the first and second elements 14, 18, takes the form of a laminate layer, such as an adhesive layer.

[0102] To assemble the control unit 10 using the lamination process, the first element 14 is pre-formed using the thermoforming process as described previously and placed in a mold. The second element 18 is formed using a similar process as described previously and placed in a facing mold. The adhesive layer 22 is then applied to either the first or second element 14, 18. 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.

[0103] Once the adhesive layer 22 is applied to the first or second element 14, 18, the molded parts are brought together to exert pressure on them, trapping the adhesive layer 22 between the first and second element 14, 18. Heat is then applied to the structure, causing the adhesive to conform precisely to the shape of the first and second element 14, 18 and bond the parts together. The presence of the adhesive on the second element 18 is advantageous because it forms a protective layer for the electronic components and circuits during the heating phase. Furthermore, as the adhesive layer heats up and transitions from a solid to a liquid state, this phase change of the adhesive layer 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 14, 18 together in a rigid structure, with the adhesive forming an intermediate layer 22 between the two.

[0104] In another embodiment (not shown), where an adhesive layer of laminate is used to hold the control unit elements together, the need for two base elements 14, 18 can be eliminated if the graphic features are placed directly into a mold instead of being applied to a first element 14. The adhesive is then applied directly into the mold onto the graphic features and joined with the second element 18 to form a two-layer structure, with the graphic features being embedded or embossed on the surface of the adhesive layer.

[0105] 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.

[0106] One advantage of adhesive lamination is that high temperatures and pressures are not required during the assembly process, and the printed electronic circuit is encapsulated using only a flexible adhesive layer that can be deformed at relatively low temperatures. Suitable materials for lamination include resins, vinyls, and ethylene copolymer resins. The flexible laminate material can be hardened by cooling or curing (e.g., UV curing).

[0107] Fig. Figure 15 is a schematic, perspective view of a laminated control unit structure 110, which can be achieved using the lamination process previously described for the encapsulation layer of laminate 122 and which is applied in a structure with a laminated circuit-supporting element 114 and a second laminated element 118.

[0108] Further embodiments provide for a hybrid arrangement of a laminated control unit structure in a part of the vehicle, which is integrated in a common arrangement into a control unit structure formed by injection molding. 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.

[0109] Fig. Figure 16 shows a possible configuration of the second element 18, which can be used to form part of the control unit 10 in an embodiment where the control unit 10 takes the form of a display unit. The in Fig. The configuration shown in Figure 16 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 for the unit 10.

[0110] The printed electronics are applied to the backlight layer 73, which provides a supporting structure to the second element 18 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 under the control of a microprocessor (not shown) to control the LCD elements as desired.A series of color filter elements 80, typically RGB filter elements, is applied to the transistor layer 78. The color filter elements 80 are interspersed with further structural supports 82, similar to the LCD elements 74. The structural supports 76, 82 can be made of the same material and can, in fact, be integral supports extending through each layer of the arrangement. Before applying an antireflective coating 86, such as glass or acrylic, a second polarizing layer 84 is applied to the color filter elements 80 to provide the second element 18 with a suitable surface finish. A heat sink arrangement in the form of a thermally conductive layer (not shown), and optionally an active heat transfer component 88, as previously described, can also be integrated into the laminated structure.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 bends. In particular, the shape of the supports 76 is chosen so that the pressure exerted on them is distributed evenly, even when the arrangement is bent. For example, the supports can be designed in the form of V-shaped structures that retain their ability to provide support even when bent.

[0111] 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 the printheads used to form the LCD elements 74 can include a first liquid crystal material, provided in selected printheads, and a second, different material, provided 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. If the final display unit 10 is required to have some flexibility, the supports 76 can be formed from silicon to provide a degree of support while also allowing the necessary flexibility.

[0112] 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.

[0113] Fig. Figure 17 shows the arrangement of the support elements 76 which, as previously described, were formed using a 3D printing process, while in Fig. 18 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.

[0114] The LCD elements 74 are operated in a manner known in engineering 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.

[0115] In another embodiment (not shown), the structural support elements 76 can be formed within the second element 18 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 18.

[0116] The embodiments in the Fig. 16, Fig. 17 to Fig. Eighteen of the displays described were liquid crystal displays, but other types of displays can also be used in the invention, such as LEDs, OLEDs, AMOLEDs, quantum dot displays, electrophoretic and electrowetting displays. The display elements can be formed by using different inks to print on various components, such as those mentioned above.

[0117] It should be noted that many modifications to the above examples can be made without departing from 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 interface and / or a surface on which information is displayed to a user is required (e.g., a control panel in an electrical device).In this sense, the A-surface of the control unit in none of the aforementioned embodiments need have 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.

[0118] The previously described heat-conducting elements 70 can be incorporated into a control unit as described with reference to one of the previous figures.

Claims

[1] Control unit (10) for a device (12), wherein the control unit (10) comprises: a component-supporting element (14; 18) provided with at least one electronic component (30, 32, 34, 36, 38; 60, 62, 73, 74, 78) configured to provide a function of the device (12); wherein the component-supporting element (14; 18) is formed from a material that is malleable at least during assembly of the control unit (10); a second element (18) that defines a user interaction interface (16) visible to a user of the device (12) during use; an encapsulation layer (22, 122) made of laminate, which encapsulates at least one part of the electronic component or components (30, 32, 34, 36, 38; 60, 62; 73, 74, 78); wherein the second element (18) is provided with at least one further electronic component, such that the electronic component or components (30, 32, 34, 36, 38; 60, 62; 73, 74, 78) are arranged on the component-supporting element (14; 18) and the at least one further electronic component on the second element (18) are arranged between the component-supporting element (14; 18) and the second element (18) within the encapsulation layer (22, 122) made of laminate; and wherein the user interaction interface (16) is designed to receive a user command, and wherein the electronic component or components (30, 32, 34, 36, 38; 60, 62; 73, 74, 78) are operable in response to the user command, the control unit (10) further comprises: a piezoelectric layer adjacent to the user interaction surface (16) to enable control of the electronic component(s) (30, 32, 34, 36, 38; 60, 62; 73, 74, 78) when the user applies the user command in the form of pressure on the user interaction surface (16). [2] Control unit (10) according to claim 1, wherein the component-supporting element (14; 18) remains malleable after complete assembly of the control unit (10). [3] Control unit (10) as claimed in a previous claim, wherein the second element (18) is spaced apart from the component-supporting element (14; 18) by the encapsulation layer (22, 122) made of laminate to define at least a three-layer structure for the control unit (10). [4] Control unit (10) as claimed in a previous claim, comprising a component-supporting surface that supports the electronic component or components (30, 32, 34, 36, 38; 60, 62; 73, 74, 78), wherein the component-supporting surface is located on the back side of the component-supporting element (14; 18) facing the user interaction surface (16). [5] Control unit (10) as claimed in a previous claim, wherein the electronic component or components (30, 32, 34, 36, 38; 60, 62; 73, 74, 78) form part of a printed electronic circuit comprising a plurality of conductors (38) for conducting current to at least one electronic component (30, 32, 34; 60, 62; 73, 74, 78). [6] Control unit (10) according to claim 5, wherein the conductor tracks (38) together with the user interaction surface (16) 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, 36, 38; 60, 62; 73, 74, 78) of the printed electronic circuit in order to ensure trace redundancy in the event of breakage and / or failure of one or more of the conductor tracks (38). [8] Control unit (10) as claimed in a previous claim, comprising an additional layer (50; 52) provided on the user interaction surface (16) to aesthetically complete the control unit (10). [9] Control unit (10) according to claim 8, wherein the additional layer (50; 52) is a veneer that complements a surface of the device (12) in which the control unit (10) is used. [10] Control unit (10) according to claim 8 or claim 9, wherein the additional layer (50; 52; 86) is a protective layer. [11] Control unit (10) according to one of claims 8 to 10, wherein the additional layer (50; 52) is an injection-molded layer. [12] Control unit (10) according to one of claims 8 to 11, wherein the additional layer (50; 52) is provided with one or more recesses. [13] Control unit (10) as claimed in a previous claim, wherein the user interaction interface (16) is provided with at least one graphic feature (24) to give the user a hint of at least one function of the electronic component (30, 32, 34, 36, 38; 60, 62; 73, 74, 78). [14] Control unit (10) according to one of claims 1 to 13, wherein the component-supporting element (14; 18) is provided with a plurality of structural supports (76) to increase the stiffness of the control unit (10). [15] Control unit (10) according to claim 14, wherein the structural supports (76) are penetrated between the electronic components (30, 32, 34, 36, 38; 60, 62; 73, 74, 78). [16] Control unit (10) according to any one of claims 1 to 15, configured for use in a vehicle (12). [17] Control unit (10) according to claim 16, wherein the at least one electronic component (30, 32, 34, 36, 38; 60, 62; 73, 74, 78) 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. [18] Control unit (10) according to any one of claims 1 to 17, wherein the encapsulation layer is formed from a laminate of a material which is flexible when heated and less flexible or rigid when cooled or cured. [19] Control unit (10) according to any one of claims 1 to 18, wherein the control unit (10) has a curved, wave-like or non-planar shape. [20] Device (12) comprising a control unit (10) as claimed in any one of claims 1 to 19. [21] Device (12) according to claim 20 in the form of a vehicle (12). [22] Method for assembling a control unit (10) for a device (12), the method comprising: Preforming of a component-bearing element (14; 18) in a first preforming step; wherein the component-supporting element (14; 18) is formed from a material that is malleable at least during the assembly of the control unit (10); Preforming a second element (18) in a second preforming step, wherein the second element (18) defines a user interaction surface (16) that is visible to a user of the device (12) during use; and Providing at least one electronic component (30, 32, 34, 36, 38; 60, 62; 73, 74, 78) on the component-supporting element (14; 18) to provide a function of the device (12) in use; Providing the second element (18) with at least one further electronic component; After the first and second preforming steps, a flexible laminate material is placed between the component-bearing element (14; 18) and the second element (18) to form an encapsulation layer (22, 122) of laminate on the at least one electronic component (30, 32, 34, 36, 38; 60, 62; 73, 74, 78), wherein the encapsulation layer (22, 122) encapsulates at least a part of the electronic component or each electronic component (30, 32, 34, 36, 38; 60, 62; 73, 74, 78); wherein the second element (18) is provided with at least one further electronic component, such that the electronic component or components (30, 32, 34, 36, 38; 60, 62; 73, 74, 78) are arranged on the component-supporting element (14; 18) and the at least one further electronic component on the second element (18) are arranged between the component-supporting element and the second element (14, 18) within the encapsulation layer (22, 122) made of laminate; and wherein the user interaction interface (16) is designed to receive a user command, and wherein the electronic component or components are operable in response to the user command, the control unit (10) further comprises: a piezoelectric layer adjacent to the user interaction surface (16) to enable control of the electronic component(s) (30, 32, 34, 36, 38; 60, 62; 73, 74, 78) when the user applies the user command in the form of pressure to the user interaction surface. [23] Method according to claim 22, wherein the preforming step of the component-supporting element (14; 18) in the first preforming step comprises injection molding of the component-supporting element (14; 18).

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