ILLUMINATED TRIM COMPONENT AND MANUFACTURING PROCESS

Abstract

A trim element, comprising: a flexible layer; a support, the flexible layer being fixed to the support, the flexible layer comprising an outer presentation surface layer, a translucent layer and a light source, the light source being fixed to one side of the translucent layer which is opposite one side of the translucent layer fixed to the outer presentation surface layer, the outer presentation surface layer being translucent; and a masking layer situated between the outer presentation surface layer and the translucent layer, the masking layer having gaps in which no masking layer is situated between the outer presentation surface layer and the translucent layer.

Description

Title of the invention: ILLUMINATED TRIM COMPONENT AND MANUFACTURING METHOD

[0001] CROSS-REFERENCE TO RELATED REQUESTS

[0002] This application claims the benefit of U.S. Provisional Patent Application Serial No. 63 / 399 486 filed on August 19, 2022. technical field

[0003] Exemplary embodiments of this disclosure relate to illuminated trim components.

[0004] BACKGROUND

[0005] In order to perform detection through a soft surface, such as one consisting of a substrate, foam, and a skin material, the sensor is typically located behind the substrate and must detect through the entire stack of materials. This can cause several problems. The sensitivity of such an arrangement may be reduced due to the fundamental operation of a capacitive sensor. For the same reason, the signal-to-noise ratio may be lower, making it more difficult to interpret the operator's interaction with the sensing element. These conditions affect the proximity at which the sensing elements (and icons) can be placed.

[0006] Consequently, it is desirable to provide an improved illuminated trim component.

[0007] BRIEF SUMMARY

[0008] The disclosure of this application aims to overcome the drawbacks of these systems by bringing the detection and lighting elements as close as possible to the first surface of the room, thereby eliminating many layers in the detection and lighting path. The construction of the disclosed embodiments uses materials that are themselves flexible and, in combination with the foam now located behind the elements, provide maximum flexibility. The sensitivity of the disclosed embodiments is optimal, and the signal-to-noise ratio is also optimal with this arrangement. With the significantly reduced light path of this invention, light transmission losses are minimized, as is color shift. The embodiments disclosed herein actively address light loss by incorporating obscuring features between icons / symbols.

[0009] A trim element is disclosed comprising: a flexible layer, a support, the flexible layer being fixed to the support, the flexible layer comprising a layer of external presentation surface, a translucent layer and a light source, the light source being fixed to one side of the translucent layer that is opposite one side of the translucent layer fixed to the external presentation surface layer, the external presentation surface layer being translucent; and a masking layer being situated between the external presentation surface layer and the translucent layer, the masking layer having gaps in which no masking layer is situated between the external presentation surface layer and the translucent layer.

[0010] In addition to one or more of the features described above, or as an alternative to one of the preceding embodiments, further comprising printed electronic components to heat the external presentation surface layer, the printed electronic components being located between the masking layer and the translucent layer.

[0011] In addition to one or more of the features described above, or as an alternative to one of the preceding embodiments, the printed electronic components to heat the external presentation surface layer are located behind or above the masking layer and are not located in the spaces.

[0012] In addition to one or more of the features described above, or as an alternative to one of the preceding embodiments, further comprising switches for controlling the printed electronic components to heat the external presentation surface layer, the switches being located between the masking layer and the translucent layer and wherein the switches are located behind or above the masking layer and are not located in the gaps.

[0013] In addition to one or more of the features described above, or as an alternative to one of the preceding embodiments, the switches are capacitive sensor elements.

[0014] In addition to one or more of the features described above, or as an alternative to one of the preceding embodiments, further comprising switches, the switches being located between the masking layer and the translucent layer and wherein the switches are located behind or above the masking layer and are not located in the gaps.

[0015] In addition to one or more of the features described above, or as an alternative to one of the preceding embodiments, the switches are capacitive sensor elements.

[0016] In addition to one or more of the features described above, or as an alternative to one of the preceding embodiments, the light source is a plurality of light-emitting diodes (LEDs).

[0017] In addition to one or more of the features described above, or as an alternative to one of the preceding embodiments, the translucent layer is a translucent foam.

[0018] In addition to one or more of the features described above, or as an alternative to one of the preceding embodiments, the external presentation surface layer is a skin formed from a thermoplastic polyolefin (TPO).

[0019] In addition to one or more of the features described above, or as an alternative to one of the preceding embodiments, the light source is a plurality of light-emitting diodes (LEDs), the translucent layer is a translucent foam, and the external presentation surface layer is a skin formed from a thermoplastic polyolefin (TPO).

[0020] In addition to one or more of the features described above, or as an alternative to one of the preceding embodiments, the light source is a plurality of light-emitting diodes (LEDs), the translucent layer is a translucent foam, and the external presentation surface layer is a skin formed from a thermoplastic polyolefin (TPO).

[0021] In addition to one or more of the features described above, or as an alternative to one of the preceding embodiments, the external presentation surface layer has a plurality of hidden icons that are only visible from an external presentation surface of the external presentation surface layer when illuminated by the light source.

[0022] In addition to one or more of the features described above, or as an alternative to one of the preceding embodiments, further comprising microswitches or pressure dome switches fixed adjacent to the light source.

[0023] In addition to one or more of the features described above, or as an alternative to one of the preceding embodiments, traces for the light source and contact pads are printed on the support or applied via a transfer layer.

[0024] In addition to one or more of the features described above, or as an alternative to one of the preceding embodiments, the external presentation surface layer is a translucent skin formed from one of the following: a thermoplastic polyolefin (TPO), a sheet, artificial leather, leather or a textile.

[0025] A method for forming a trim element is disclosed, comprising: attaching a flexible layer to a substrate, the flexible layer comprising an external presentation surface layer, a translucent layer and a light source, the light source being attached to one side of the translucent layer that is opposite to one side of the translucent layer attached to the external presentation surface layer, the external presentation surface layer being translucent; and a masking layer being situated between the external presentation surface layer and the translucent layer, the masking layer having gaps in which no masking layer is situated between the external presentation surface layer and the translucent layer.

[0026] In addition to one or more of the features described above, or as an alternative to one of the preceding embodiments, further comprising printed electronic components to heat the external presentation surface layer, the printed electronic components being located between the masking layer and the translucent layer.

[0027] In addition to one or more of the features described above, or as an alternative to one of the preceding embodiments, the printed electronic components to heat the external presentation surface layer are located behind or above the masking layer and are not located in the spaces.

[0028] In addition to one or more of the features described above, or as an alternative to one of the preceding embodiments, further comprising switches for controlling the printed electronic components to heat the external presentation surface layer, the switches being located between the masking layer and the translucent layer and wherein the switches are located behind or above the masking layer and are not located in the gaps.

[0029] In addition to one or more of the features described above, or as an alternative to one of the preceding embodiments, the switches are capacitive sensor elements.

[0030] In addition to one or more of the features described above, or as an alternative to one of the preceding embodiments, the external presentation surface layer is a translucent skin formed from one of the following: a thermoplastic polyolefin (TPO), a sheet, artificial leather, leather, or a textile. BRIEF DESCRIPTION OF FIGURES

[0031] The following descriptions are in no way intended to be exhaustive. With reference to the accompanying drawings, similar elements are numbered in the same way:

[0032] [Fig. 1] is a cross-sectional view of a trim component in accordance with this disclosure;

[0033] [Fig.2] is a cross-sectional view of a trim component in accordance to the present disclosure;

[0034] [Fig.2A] is a cross-sectional view of a trim component in accordance with this disclosure;

[0035] [Fig.3] is a cross-sectional view of a trim component in accordance with this disclosure;

[0036] [Fig.3A] is a cross-sectional view of a trim component in accordance with this disclosure;

[0037] [Fig.4] is a cross-sectional view of a trim component in accordance with this disclosure;

[0038] [Fig.4A] is a cross-sectional view of a trim component in accordance with this disclosure;

[0039] [Fig. 5] is a cross-sectional view of a trim component in accordance with this disclosure; and

[0040] [Fig. 5A] is a cross-sectional view of a trim component in accordance with this disclosure. DETAILED DESCRIPTION

[0041] A detailed description of one or more embodiments of the disclosed apparatus and method is presented here by way of example and not limitation with reference to the accompanying FIGs.

[0042] Referring now to [Fig. 1], a perspective view of a trim component or trim element 10 with a flexible layer 12 according to a non-limiting embodiment of this disclosure is illustrated. In a non-limiting embodiment, the trim component may be an interior trim piece of a vehicle. Non-limiting examples include armrests, center consoles, interior trim panels, parts of a dashboard, and any other suitable part of a vehicle.

[0043] The flexible layer 12 may comprise an outer presentation surface layer 14 and a translucent layer 16. According to a non-limiting embodiment of this disclosure, the outer presentation surface layer 14 may be a translucent skin formed from thermoplastic polyolefin (TPO), foil, artificial leather, leather, textile, or other equivalent material, etc., with a plurality of hidden icons that are visible only from an outer presentation surface 20 of the outer presentation surface layer 14 when illuminated by a light source 18, illustrated by a layer 18 located behind the outer presentation surface layer 14. Alternatively, the icons are visible without being illuminated (e.g., printed with a visible index that can be illuminated from its back side to make it brighter) and they are in in addition illuminated by the light source so that they are clearly visible at night or when the area around trim element 10 is dark.

[0044] In yet another embodiment, the external presentation surface layer 14 may include visible icons and hidden icons, where the hidden icons are only visible from an external presentation surface 20 of the external presentation surface layer 14 when illuminated by the light source located behind the external presentation surface layer 14 and the visible icons may be illuminated by the light source located behind the external presentation surface layer 14 or, alternatively, the visible icons are not illuminated by the light source located behind the external presentation surface layer 14.

[0045] It is also understood that materials other than thermoplastic polyolefin (TPO) may be used for the external presentation surface layer 14 (for example, leather, urethane, thermoplastic polyurethane (TPU) or any other suitable material).

[0046] The translucent layer 16 may include a foam or spacer located between the light source 18 and the external presentation surface layer 14. In one embodiment, the light source 18 may include a plurality of light-emitting diodes (LEDs), including a layer of printed electronic components. The light source 18 is fixed to one side of the translucent layer 16 that is opposite the side of the translucent layer 16 fixed to the external presentation surface layer 14.

[0047] It is also shown that the light source 18 is attached to a support layer 22, which may be translucent or opaque. In a non-limiting embodiment, the light source 18 is a separate layer attached to the support layer 22. Alternatively, the light source 18 may be printed onto the support layer 22 or applied via a transfer sheet. A masking layer 24 is located between the outer presentation surface layer 14 and the translucent layer 16 to block the light emitted by the light source 18. For example, a masking layer 24 may comprise an opaque material. A plurality of gaps 26 are provided where no masking layer 24 is applied so that the light from the light source can pass through the icons located in the outer presentation surface layer 14.

[0048] As such and in this embodiment, a trim element 10 with a flexible layer 12 attached to a support 22 is provided. The flexible layer 12 may comprise an external presentation surface layer 14 and a translucent layer 16 and a light source 18 located behind the surface layer of external presentation 14. A masking layer 24 located between the external presentation surface layer 14 and the translucent layer 16 is also provided.

[0049] Referring now to [Fig. 2], another embodiment of the present disclosure is provided. Here, printed electronic components 28 for heating the external presentation surface layer 14 are located between the masking layer 24 and the translucent layer 16. As illustrated, the printed electronic components 28 for heating the external presentation surface layer 14 are located behind or above the masking layer 24 (see [Fig. 2A]) and are not located in the spaces 26. As mentioned above, and in a non-limiting embodiment, the light source 18 is a separate layer attached to the support layer 22. Alternatively, the light source 18 may be printed on the support layer 22 or applied via a transfer sheet.

[0050] Referring now to [Fig. 3], another embodiment of the present disclosure is provided. Here, printed electronic components 30, including switches such as capacitive sensor elements for controlling printed electronic components 28 to heat the external presentation surface layer 14, are located between the masking layer 24 and the translucent layer 16. Although it is stated that the switches may control the printed electronic components 28 to heat the external presentation surface layer 14 as an alternative, the switches may control any other vehicle function, including, but not limited to, seat position, climate control, autonomous driving features, or anything else required as a human-machine interface. As illustrated, the printed electronic components 30 are located behind or above (See [Fig. 3].3A]) of the masking layer 24 and are not located in the spaces 26. As mentioned above and in a non-limiting embodiment, the light source 18 is a separate layer attached to the support layer 22. Alternatively, the light source 18 can be printed on the support layer 22 or applied via a transfer sheet.

[0051] Referring now to [Fig. 4], another embodiment of the present disclosure is provided. Here, only the printed electronic components 30, including switches such as capacitive switches for controlling other functions, are located between the masking layer 24 and the translucent layer 16. As illustrated, the printed electronic components 30 are located behind or above (see [Fig. 4A]) the masking layer 24 and are not located in the spaces 26. In this embodiment, no printed electronic components 28 for heating the external presentation surface layer 14 are provided. As mentioned above, and in a non-limiting embodiment, the light source 18 is a separate layer attached to the support layer 22. Alternatively, the light source 18 can be printed onto the support layer 22 or applied via a transfer sheet.

[0052] With reference now to [Fig. 5] and [Fig. 5A], another embodiment of the present disclosure is provided. Here, mechanical pressure-dome switches, micro-switches, or any equivalent switches 50 may be located beside or near the layer comprising the light source 18. Although the pressure-dome switches or micro-switches 50 illustrated in [Fig. 5] and [Fig. 5A] are similar to the embodiments of [Fig. 4] and [Fig. 4A], the pressure-dome switches or micro-switches 50 may also be included in the embodiments illustrated in [Fig. 1] to [Fig. 3A].

[0053] The terminology used herein is intended to describe particular embodiments only and is not intended to limit this disclosure. It shall be further understood that the terms "includes" and / or "comprising", when used in this specification, specify the presence of declared features, integers, steps, operations, elements and / or components, but do not exclude the presence or addition of one or more other features, integers, steps, operations, elements, components and / or groups thereof.

[0054] Although this disclosure has been described with reference to one or more exemplary embodiments, those skilled in the art will understand that various changes can be made and that equivalents can be substituted for elements thereof without departing from the scope of this disclosure. Furthermore, numerous modifications can be made to adapt a particular situation or material to the teachings of this disclosure without departing from its essential scope. Accordingly, it is intended that this disclosure will not be limited to the particular embodiment disclosed as the best envisaged embodiment for carrying out this disclosure, but that this disclosure will include all embodiments falling within the scope of the claims.

Claims

Demands

1. A trim element (10), comprising: a flexible layer (12); a support (22), the flexible layer (12) being attached to the support (22), the flexible layer (12) comprising an outer presentation surface layer (14), a translucent layer (16) and a light source (18), the light source (18) being attached to one side of the translucent layer (16) which is opposite one side of the translucent layer (16) attached to the outer presentation surface layer (14), the outer presentation surface layer (14) being translucent; and a masking layer (24) situated between the outer presentation surface layer (14) and the translucent layer (16), the masking layer (24) having gaps where no masking layer (24) is situated between the outer presentation surface layer and the translucent layer;in which the external presentation surface layer (14) has a plurality of hidden icons that are only visible from an external presentation surface of the external presentation surface layer when illuminated by the light source.

2. A trim element according to claim 1, further comprising printed electronic components (28) for heating the external presentation surface layer (14), the printed electronic components (28) being located between the masking layer (24) and the translucent layer (16).

3. Trim element according to claim 2, wherein the printed electronic components (28) for heating the external presentation surface layer are located behind or above the masking layer (24) and are not located in the gaps.

4. A trim element according to claim 2, further comprising switches for controlling the printed electronic components (28) to heat the external presentation surface layer, the switches being located between the masking layer (24) and the translucent layer (16) and wherein the switches are located behind or above the masking layer and are not located in the gaps.

5. Trim element according to claim 4, wherein the switches are capacitive sensor elements.

6. Trim element according to claim 1, further comprising switches, the switches being located between the masking layer (24) and the translucent layer (16) and wherein the switches are located behind or above the masking layer and are not located in the gaps.

7. Trim element according to claim 6, wherein the switches are capacitive sensor elements.

8. Trim element according to claim 1, wherein the light source (18) is a plurality of light-emitting diodes (LEDs).

9. A trim element according to claim 1, wherein the translucent layer (16) is a translucent foam.

10. Trim element according to claim 1, wherein the external presentation surface layer is a skin formed from a thermoplastic polyolefin (TPO).

11. Trim element according to claim 1, wherein the light source (18) is a plurality of light-emitting diodes (LEDs), the translucent layer (16) is a translucent foam and the external presentation surface layer (14) is a skin formed from a thermoplastic polyolefin (TPO).

12. Trim element according to claim 4, wherein the light source is a plurality of light-emitting diodes (LEDs), the translucent layer (16) is a translucent foam and the external presentation surface layer (14) is a skin formed from a thermoplastic polyolefin (TPO).

13. Trim element according to claim 1, further comprising micro-switches or pressure-dome switches fixed adjacent to the light source.

14. Trim element according to claim 1, wherein traces for the light source (18) and contact pads are printed on the substrate or applied via a transfer layer.

15. A method for forming a trim element, comprising: attaching a flexible layer (12) to a substrate, the flexible layer (12) comprising an external presentation surface layer (14), a translucent layer (16) and a light source (18), the light source (18) being attached to one side of the translucent layer (16) which is opposite one side of the translucent layer (16) attached to the outer presentation surface layer, the outer presentation surface layer (14) being translucent; and a masking layer (24) being situated between the outer presentation surface layer (14) and the translucent layer (16), the masking layer (24) having gaps in which no masking layer is situated between the outer presentation surface layer and the translucent layer in which the outer presentation surface layer (14) has a plurality of hidden icons which are visible only from an outer presentation surface of the outer presentation surface layer when illuminated by the light source.

16. A method according to claim 15, further comprising printed electronic components (28) for heating the external presentation surface layer (14), the printed electronic components (28) being located between the masking layer (24) and the translucent layer (16).

17. A method according to claim 16, wherein the printed electronic components (28) for heating the external presentation surface layer are located behind or above the masking layer (24) and are not located in the gaps.

18. A method according to claim 16, further comprising switches for controlling the printed electronic components to heat the external presentation surface layer (14), the switches being located between the masking layer (24) and the translucent layer (16) and wherein the switches are located behind or above the masking layer (24) and are not located in the gaps.

19. Method according to claim 18, wherein the switches are capacitive sensor elements.

20. A method according to claim 15, wherein the external presentation surface layer (14) is a translucent skin formed from one of the following: a thermoplastic polyolefin (TPO), a sheet, artificial leather, leather or a textile.

21. A trim element according to claim 1, wherein the outer presentation surface layer (14) is a translucent skin formed from one of the following: a polyolefin thermoplastic (TPO), a sheet, artificial leather, leather or textile.

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