Integral 3D structure for creating ui, related device and methods of manufacture and use

Abstract

An integrated functional multilayer structure (100, 200, 1100, 1200) for constructing a gesture user interface (UI) includes: a flexible, 3D formable substrate film (202), comprising a first surface (202a) facing an environment of the structure and a user therein, and an opposing second surface (202b) facing the interior of the structure, wherein the remaining material of the first surface (202a) and the second surface (202b) and the substrate film (202) therebetween partially defines a three-dimensional protrusion (101) extending from a plane (2020) of the surrounding substrate film material and formed by a partially stretched and molded material of the substrate film, the protrusion (101) preferably being located in the... The multilayer structure defines a continuous multi-sided knob (100, 200) or recess (1100, 1200) shape by a plurality of substantially vertical or inclined and, where appropriate, at least partially curved sidewalls (104) that are perceptible by touch; a circuit system (206) disposed on the substrate film and comprising a plurality of conductive traces, electrodes and / or components configured to detect touches on the top (201) of two or more of the plurality of sidewalls and preferably on one of the protrusions; and preferably at least one filler layer (208) of thermoplastic filler material configured, where appropriate, to be (injection) molded or cast onto the substrate film to at least partially embed the circuit system and, where appropriate, also embed the volume defined by the protrusion shape and the plane. A related manufacturing method is presented.

Description

[Technical Field]

[0001] This invention generally relates to a functional, integrated structure that incorporates various functional features such as electronic, mechanical, or optical elements or different combinations thereof. Specifically, but not exclusively, this invention focuses on providing user interface (UI) solutions for electronic devices via such integrated structures. [Previous Technology]

[0002] In the context of different functional groups, such as in the field of electronic devices and electronic products, there are many different stacked assemblies and multilayer structures. The motivations behind the integration of functionalities involving, for example, electronic, mechanical, or optical features can be as diverse as the relevant use cases. When the resulting solution ultimately exhibits a multilayered nature, the pursuit is relatively more often for component size reduction, weight reduction, cost savings, or simply efficient integration. Furthermore, the associated use cases may relate to product packaging or encapsulation, visual design of device housings, wearable electronics, personal electronic devices, displays, detectors or sensors, vehicle interiors, antennas, tags, vehicle electronics, etc.

[0003] Electronic devices, such as electronic components, integrated circuits (ICs), and conductors, can typically be mounted on substrate elements using a plurality of different techniques. For example, off-the-shelf electronic devices, such as various surface mount devices (SMDs), can be mounted on the surface of a substrate, which ultimately forms a multilayered internal or external interface layer. Additionally, techniques categorized under the term "printed electronics" can be applied to substantially directly and cumulatively produce electronic devices onto an associated substrate. In this context, the term "printing" refers to various printing techniques capable of producing electronic devices / electrical components from printed materials in a substantially additive printing process, including but not limited to screen printing, flexography, and inkjet printing. The substrate used can be a flexible and organic printing material; however, this is not always the case.

[0004] Furthermore, the concept of Injection Molded Structure Electronics (IMSE) involves constructing functional devices and their corresponding parts in a multi-layered structure to encapsulate electronic functionality as seamlessly as possible. A key characteristic of IMSE is that the electronics are typically manufactured in a true 3D (non-planar) form based on a 3D model of the entire target product, part, or overall design. To achieve the desired 3D layout of the electronics on a 3D substrate and in the associated final product, a two-dimensional (2D) approach to the electronics assembly may still be used to set the electronics on an initial planar substrate such as a thin film. Therefore, the substrate housing the electronics can be formed into the desired three-dimensional (i.e., 3D) shape and, for example, by overmolding with suitable plastic materials covering and embedding components such as those underlying the electronics, thus protecting and potentially concealing these components from environmental influences. Other layers and components can be naturally added to the construction.

[0005] Many electronic devices require, or at least benefit from, a user interface that enables users to control the device and receive feedback from or through it. As the integration and overall complexity of electronic devices appear to increase overall, while their size can decrease simultaneously, designing a viable UI without any major disadvantages is not always straightforward. Even more modern UIs, such as rotatable controllers, touchscreens, and touchpads, can easily result in functionally unfortunate limitations, counterintuitive features, fragility, or at least ergonomic challenges, thereby causing fatigue without significantly impacting user health, and occasionally even being considered dangerous depending on the context of UI use: for example, situations where the user should be focusing their gaze on something outside the UI but is still tempted or required to use it, or situations where the use of the UI requires a large amount of visual attention; such situations can easily occur, for example, in traffic. Among various UIs, providing ergonomically awkward flat touch-sensitive surfaces is indeed very common, often requiring users to gaze at or look at the surface while operating devices such as smartphones, tablets, multimedia devices, or electronic components and related functions within various vehicles. Providing input can easily become a risky and cumbersome training process. Another very likely UI is a rotary handle or knob, an electromechanical knob / button, which allows users to interact by physically turning the knob or, for example, pushing (moving) the knob in the forward / backward or left / right direction and pushing or tapping it from the top. In addition to having very limited practical control logic, all such solutions are prone to failure and further require a high level of user attention to avoid erroneous input. [Summary of the Invention]

[0006] The object of the present invention is to at least mitigate one or more of the disadvantages associated with known solutions in the context of UI and associated electronic or at least electrically controllable devices.

[0007] This objective is achieved by various embodiments of integrated functional multilayer structures and related methods of using or providing multilayer structures.

[0008] According to one embodiment, an integrated functional multilayer structure for constructing a gesture user interface (UI) includes a flexible, 3D formable substrate film, comprising a first surface facing an environment of the structure and a user therein, and an opposing second surface facing the interior of the structure, wherein the first surface and the second surface, and the remaining material of the substrate film therebetween, partially and collectively define a three-dimensional protrusion extending from a plane of surrounding substrate film material and formed by partial stretching and molding of the substrate film, the protrusion defining a continuous multi-sided knob, groove, or other shape in the multilayer structure by a plurality of substantially vertical or inclined (relative to the plane) and, where appropriate, at least partially curved sidewalls that are perceptible by touch. A circuit system, such as a control and / or detection circuit system, disposed on the substrate film (e.g., directly onto the substrate film, or specifically, on one surface of the substrate film, and / or to any underlying layer, such as another (substrate) film), and at least partially housed by a volume defined by the shape of the protrusion and the plane, the circuit system comprising a plurality of conductive traces, electrodes and / or components configured to detect touches of two or more of the plurality of sidewalls, preferably the top (i.e., the top of a knob or the bottom of a recess) of one of the protrusions; and preferably at least one filler layer of thermoplastic filler material, configured as appropriate to be molded (e.g., injection molding or casting) onto the substrate film to at least partially embed the circuit system and at least partially fill the volume.

[0009] In various embodiments, at least a portion of the circuitry is attached to or generated on the second surface of the substrate film, or more specifically, attached to or generated to the second surface of the substrate film. For example, such elements may be one or more electrodes, sensing elements such as attached conductors (traces), or associated drive or control circuitry.

[0010] The main device may include embodiments of the multi-layered structures described or characterized herein. The main device may be or include at least one of the following: a console, a vehicle console, a door, a top panel, a multimedia device, a computer device, a home appliance (e.g., a cooking appliance, a cleaning appliance, a cooling device such as a refrigerator or freezer, a washer, a dryer, a heater, a lawnmower, or a lighting device), a vehicle, a road vehicle (e.g., a car or truck), a vessel (e.g., a small boat or ship), an aircraft or general space vehicle, a personal communication device, or a control device. The multi-layered structure may be configured to form at least a portion of the UI of a console or panel of the main device.

[0011] In some embodiments, the main device may be, for example, an armrest. The device may be equipped with object sensors, such as arm or wrist sensors, and at least one capacitive, resistive, optical, and / or pressure sensor. The device may be configured to change the operability of the structure based on data provided by the sensors, which may refer to, for example, adapting or activating touch sensing in response to detecting the presence of a user's arm or wrist on the armrest.

[0012] According to another embodiment, a structure or apparatus according to any embodiment described or characterized herein may be used to obtain user input and, as appropriate, initiate control actions based on the user input.

[0013] In another embodiment, a method of manufacturing an integrated multilayer structure includes: obtaining a substrate film comprising a formable, and optionally thermoformable, material and further comprising a first surface facing an environment of the structure and a user therein, and an opposing second surface facing the interior of the structure; preferably providing a circuit system on the substrate film using printed electronics technology and / or selected mounting technology; 3D forming the substrate film such that the first surface and the second surface, and a plurality of remaining materials forming the substrate film therebetween, partially define a three-dimensional protrusion extending from a plane of surrounding substrate film material, the protrusion defining a plurality of side knobs, grooves, or other shapes in the structure by means of a plurality of substantially vertical or inclined and optionally at least partially curved sidewalls perceptible by touch; The circuit system is at least partially housed by a volume defined by the shape of the protrusion and the plane, and includes a plurality of conductive traces, electrodes and / or components configured on the substrate film to detect touches on two or more of the plurality of sidewalls and preferably on the top of one of the protrusions (i.e., the top of the knob shape or the bottom of the groove shape); and at least one filler layer of preferably thermoplastic filler material disposed on the substrate film by injection molding or casting, to at least partially embed the circuit system and at least partially fill the aforementioned volume.

[0014] The present invention naturally depends on the various advantages offered by its specific embodiments over many known UIs. Therefore, by 3D molding of a suitable substrate film, and thermoforming as appropriate, a three-dimensional, easily accessible, reliable, and ergonomically convenient smart surface for UI purposes, including user input, can be cleverly created. The film can thus be transformed into a hermetically sealed, monolithic gesture-sensitive surface, including a touch-sensitive 3D surface (if necessary), supplemented with various electronics and additional features and material layers to provide a better UI solution for the relevant use case.

[0015] The established shape may vary between embodiments, but in various preferred embodiments, a multifaceted or, specifically, a multifaceted smart surface with four side facets having a square or round top can be locally raised or lowered by 3D shaping to produce a knob or groove shape that the user can touch (knob / groove) and pinch (knob) with their fingers, and for control input purposes, and as appropriate for receiving, for example, tactile or visual feedback or output from the multi-layer structure itself or from the conduit or connection device.

[0016] By carefully designing the corners between the sidewalls or facets of the knob or recess, full, even complete 360-degree, finger movement or sliding without overflow can be achieved. The vertical or inclined surfaces of the sidewalls are preferably rounded at the corners to allow smooth movement of the user's fingers between them for both ergonomic and intuitive use. The desired number of intuitive gesture areas or sections can be configured by the sensing circuitry system used and related, software-configurable and, for example, remotely configurable (e.g., user-configurable), detection or normal operating logic at the facets and / or top of the protrusion to support the detection of all desired gestures, such as simple finger gestures that are easy to input, while also implementing a large number of more functional control logic options in applications such as graphical user interfaces (GUIs). Therefore, by establishing prominent "knobs" or descending "grooves" in the entire multi-layer structure through various embodiments of the present invention, user interface controls, even slightly complex ones, can be generated in the physical user interface using relatively simple, easy-to-adopt and easy-to-execute gesture patterns.

[0017] The multi-sided or multi-faceted 3D surfaces proposed herein offer a wide range of functionalities while still relying on effortless control logic based on, for example, single-finger or multi-finger swipe input and tap input. In some embodiments, detected input gestures may additionally or alternatively include contactless gesture input, which may, for example, involve “drawing” or pointing with one or more fingers in the air within the detection range of a multi-layered sensing element.

[0018] In various embodiments, the detected gestures may generally include, for example, parallel synchronization (two fingers, for example, lateral sliding in the same direction on opposite sidewalls / facets of the protrusion) and parallel opposite directions. However, a single finger in any segment, or specifically such as the thumb on a segment of a sidewall / facet, may be detected, while other fingers such as the index or middle finger on adjacent or opposite sides may be detected, wherein any or all of the detected fingers may be static or sliding, and movements such as lateral sliding in a particular direction on a particular sidewall / facet may be associated with control actions different from those in opposite directions or, for example, from a tapping motion. Successive sliding involving several adjacent sidewalls or general surfaces of the protrusion may also be detected.

[0019] Any of these distinguishable input gestures, including, for example, various combinations of swipe and tap logic, can be associated with unique control actions such as feature selection, activation, deactivation, or scrolling on a GUI, for example, by control logic stored in the circuit system or connected to a managed / external device, and thus potentially also involves a control display of the control device or a device connected thereto. The association can be context-dependent or generally dynamic, as will be discussed later. Needless to say, the gesture patterning implemented by various embodiments of the invention further facilitates, for example, easy and intuitive pinch-to-zoom (etc., move away, move in – how to control the zoom-in / zoom-out direction, which can be configured based on the embodiment) by detecting, for example, at least two moving fingers such as the thumb and forefinger on adjacent sidewalls / facets. In any case, 3D-shaped protruding knobs or recesses allow the user to interact naturally with various gesture combinations. For example, a simple scrolling action can be activated by, for example, sliding a finger in either lateral direction, intervening in a single sidewall / facet (e.g., menu (object) movement). The relatively parallel sidewalls / facets can then be followed by (thumb) touch logic, for example, becoming simple scroll + touch logic or "mouse logic". Executing a similar scroll logic with two relatively parallel facets but in opposite directions can trigger, for example, a faster navigation option in a menu, or activate a selected segmented GUI / UI interactive control.

[0020] The multi-layered structure, and specifically, for example, the knobs or protrusions providing recesses therein, may also integrate and / or be adjacent to several visual aids such as static vision, including, for example, informational graphics, such as instruction symbols. Alternatively or additionally, visual aids may include dynamic vision, such as dynamically controllable lighting, several LEDs as appropriate to provide guidance to the user (e.g., indication of active touch surfaces such as the sidewalls / facets or top of the structure), feedback (e.g., indication of detected gestures by means of associated visual responses such as activation light or a sequence of illumination), or other outputs such as device or specific feature status information.

[0021] In addition to providing overall UI features to a specific host device by means of embodiments such as integrating the proposed multi-layer structure into the device housing, various embodiments of the present invention can be used to provide more general control devices to replace, for example, a mouse. The control device can be further configured to detect its own rotation along a selected axis such as its vertical axis, and further configured to perform related control actions. This control device can be wired or wirelessly connected to any of several target devices to be controlled whenever needed. Therefore, an internal power source (a disposable battery, a rechargeable battery, etc.) or an external power source (e.g., via a cable connected to the target device) can be provided to power such a multi-purpose control device.

[0022] Those familiar with this technology will understand various other advantages based on the following detailed description.

[0023] The expression “several” in this document may refer to any positive integer starting from one (1), such as one, two or three.

[0024] Correspondingly, the expression “multiple” can refer to any positive integer starting from two (2).

[0025] The terms “first,” “second,” “third,” and “fourth” are used herein to distinguish one element from another (other) element and do not specifically indicate their priority or order unless otherwise expressly stated.

[0026] The exemplary embodiments of the invention presented herein are not to be construed as limiting the applicability of the appended claims. The verb "comprising" is used herein as an open-ended limitation and does not exclude the presence of features not described. Unless expressly stated otherwise, the features described in the various embodiments and, for example, the appended claims, can be freely combined with each other.

[0027] Novel features considered characteristic of the invention are particularly set forth in the appended claims. However, the invention itself, with regard to its construction and methods of operation, along with its additional objectives and advantages, will be best understood from the following description of specific exemplary embodiments when read in conjunction with the accompanying drawings.

Implementation Method

[0045] FIG1 illustrates an embodiment of the multilayer structure according to the present invention at 100. FIG2 illustrates a cross-sectional side view of the multilayer structure according to various embodiments of the present invention, such as the embodiment of FIG1, along line AA depicted in FIG1 at 200.

[0046] The multilayer structure includes at least one substrate film 202, which is preferably flexible and 3D-formable (malleable), such as a thermoformable material. In addition to film 202, the structure may include at least one other (substrate) film 212 made of the same and / or different material as one of the films 202. Film 202 includes a first side and associated first surface 202a advantageously oriented toward the use environment of the structure and, for example, a user, or specifically, a user's hand, finger, stylus, or other touch, pointing, or gripping element 180 residing in the use environment. However, film 202 may also include, for example, an opposing second side and associated second surface 202b substantially facing the interior of the structure.

[0047] The substrate film 202 and / or another film 212 or material layer included in the multilayer structure may contain at least one material selected from the group consisting of: polymers, thermoplastic materials, electrically insulating materials, polymethyl methacrylate (PMMA), polycarbonate (PC), copolyester, copolyester resin, polyimide, copolymer of methyl methacrylate and styrene (MS resin), glass, polyethylene terephthalate (PET), carbon fiber, organic materials, biomaterials, leather, wood, textiles, fabrics, metals, organic natural materials, solid wood, veneer, plywood, stem bark, bark, birch bark, cork, natural leather, natural textiles or fabric materials, naturally grown materials, cotton, wool, flax, silk, and any combination thereof.

[0048] The thickness of film 202 and, if applicable, another film 212 may vary depending on the embodiment; it may be only tens or hundreds of millimeters, or quite thick, for example, one or several millimeters.

[0049] Preferably, at least film 202 and, if applicable, another film 212 have been treated by thermoforming or other feasible (material-specific) shaping methods to define local protrusions 101 that rise from the plane 220 defined by the surrounding film material. The protrusions 101 may have several sidewalls 104 and define the sidewalls 104 and, for example, a top surface 201. 101 preferably produces a knob shape that is tactilely and advantageously visually perceptible to the user from the context of the structure, for example, easy to feel and easy to grip. Corners or edges between walls 104 and between walls 104 and the top surface 201 may be rounded or curved, and are, for example, a direct result of shaping methods used such as thermoforming. Alternatively, groove shapes may be created by the protrusions 101 in a multilayer structure, as illustrated, for example, in Figures 11 and 12, and discussed in more detail in the related description.

[0050] In various embodiments, at least partially, one or more additional layers 203 may be present on any of the walls 104, top 201, and / or surrounding films. Any additional layer 203 may, as appropriate, comprise, for example, a coating or a film. The material of the material layer may differ from one of the substrate films 202. It may include, for example, selected polymeric materials having (nano) particles for providing desired scratch resistance, anti-reflection, reflectivity, tactile and / or visual effects, and other options.

[0051] Item 208 refers to at least one filler layer preferably provided by molding it onto film 202 and, where appropriate, between film 202 and 212, wherein the film can be used as an insert in the relevant mold.

[0052] At least one filler layer may contain at least one material selected from the group consisting of: polymers, organic materials, biomaterials, composite materials, thermoplastic materials, thermosetting materials, elastic resins, PC, PMMA, ABS, PET, copolyesters, copolyester resins, nylon (PA, polyamide), polypropylene (PP), thermoplastic polyurethane (TPU), polystyrene (GPPS), thermoplastic silicone vulcanizate (TPSiV) and MS resin.

[0053] Item 206 refers to a circuit system disposed on the substrate thin film 202, i.e., directly (located on the thin film 202 itself) (typically therefore on at least one selected surface) and / or on any adjacent or subsequent thin film or other material layer of a multilayer structure. The circuit system 206 may include, for example, several electrical conductors (traces), contact pads, electrodes, and integrated circuits (ICs), such as sensor driving, reading, and / or control circuitry, or control circuitry generally relating to, for example, UI functions provided by the structure and / or some other function provided by the structure.

[0054] As described above, the circuit system 206 may be directly produced on, for example, thin film 202 (e.g., on surface 202b) and 212 (if present) and / or on other structures, multilayer material layers, or associated surfaces by selected methods such as printed electronics, screen printing, or other additive printing or general coating techniques. Alternatively, the circuit system 206 may include several mounting components, such as surface mount devices (SMDs). Therefore, non-conductive and / or conductive adhesives may be used to secure the mounting components to the carrier. In some embodiments, mechanical fastening is implemented or at least reinforced by non-conductive adhesive materials, with El solder or other highly conductive (but to a lesser extent, adhesive type) materials used for electrical connections. Preferably, the circuit system 206 is at least partially (if not completely) disposed on thin film 202 and, where appropriate, thin film 212 before the 3D shaping of the thin film (i.e., while thin films 202, 212 are still substantially planar or at least relatively planar) to avoid cumbersome 3D assembly of electronics on an already 3D shaped carrier. However, embodiments in which thin film 202 does not carry any or at least a large amount of circuit system 206 are also feasible. In these and other embodiments, for example, another substrate thin film 212 or other material layer may still control any selected circuit system 206.

[0055] If, for example, capacitive sensing is applied, the sensing electrodes of the circuit system 206 can be configured (sized, positioned, etc.) so that they are positioned as needed within a sensing area or volume defined by, for example, an associated electric field, and thereby cover, for example, selected areas on the sidewalls and / or top of the structure and / or other areas sensitive to touch (and / or, in some embodiments, non-touch gestures). For example, this type of configuration can be achieved or performed by using analog or measurement methods.

[0056] The circuit system 206 may therefore include and / or the remaining multilayer structure may include at least one component selected from the group consisting of: electronic components, electromechanical components, electro-optical components, radiative emission components, light-emitting components, light-emitting diodes (LEDs), organic LEDs (OLEDs), side-emitting LEDs or other light sources, top-emitting LEDs or other light sources, bottom-emitting LEDs or other light sources, radiation detection components, light detection or photosensitive components, photodiodes, photoelectric crystals, photovoltaic devices, sensors, micromechanical components, switches, touch switches, touch panels, proximity switches, touch sensors, atmospheric sensors, temperature sensors, pressure sensors, humidity sensors, gas sensors, proximity sensors, capacitive switches, and capacitive sensors. Projected capacitive sensors or switches, single-electrode capacitive switches or sensors, capacitive pushbuttons, multi-electrode capacitive switches or sensors, self-capacitive sensors, mutual-capacitive sensors, inductive sensors, sensor electrodes, micromechanical components, UI elements, user input elements, vibration elements, sound generating elements, communication elements, transmitters, receivers, transceivers, antennas, infrared (IR) receivers or transmitters, wireless communication elements, wireless tags, radio tags, tag readers, data processing elements, microprocessors, microcontrollers, digital signal processors, signal processors, programmable logic chips, application-specific integrated circuits (ASICs), data storage elements, electronic subassemblies, light guiding elements, light guides, lenses, and reflectors.

[0057] Preferably, one or more of the sidewalls 104 and / or the top 201 are associated with or have the circuitry 206, such as electrodes for, for example, capacitive sensing, or other sensing elements that can be connected to control circuitry, such as microcontrollers, microprocessors, or integrated IMSE nodes (component-like integrated IMSE subassemblies having a substrate, electronics, filler, and their own, optionally selected, housing), and are also preferably disposed, for example, within the structure, such as within a volume (V) substantially defined by the shape of the protrusions 101, or elsewhere in the structure and / or even outside the structure in the main body or external device. Each wall 104, which is advantageously an inner surface 202b, can be associated not only with a single but with a plurality of sensing elements, such as electrodes configured in a desired array (e.g., lateral) or matrix configuration. Alternatively or otherwise, the sensing element may be sized and positioned, and the sensing or reading circuitry may be configured by someone skilled in the art to individually cover a selected larger area or zone, and, where appropriate, to achieve more specific sensing of, for example, a user's finger in an area with more precise spatial resolution than simply covering the entire area / zone.

[0058] As mentioned above, the structure may be, and in many preferred use cases will be, connected to an external system or device 230, such as the main body of the structure, which is illustrated in FIG2 by means of a connector (e.g., an electrical connector) or connector cable 230a that may be attached to the structure and its components (e.g., a circuit system 206) in a selected manner (e.g., communication and / or power supply).

[0059] Object 210 refers to a possible body surface or structure used in the multilayer structure covered herein. In some embodiments, object 210 may be part of the body device of the multilayer structure, or object 210 may be an intermediate element. Those skilled in the art will readily understand that, alternative to or other than the multilayer structure side, a general connection between connector 203a or the electronics of the multilayer structure and the electronics of the body / external device can be achieved via object 210. The material of object 210 may include any material deemed advantageous, such as any of the materials listed above (e.g., plastics, metals, organic or natural materials).

[0060] Object 140 relates to one or more possible visual indicators provided within the structure (e.g., on film 202). These indicators may indicate to the user the location of gesture-sensitive areas, how input should be provided, feedback in response to detected user input, the state of the UI or a specific feature of the UI, or the state of the subject / connected external device. The indicators may be static, such as graphic printing or otherwise produced on the surface of the subject, such as film 202, possibly coating 203, or another layer of the structure. Alternatively or concurrently, the indicators may have temporally dynamic components. For example, by means of an embedded light source such as an (O)LED, the structure may be configured to provide the user with dynamic visual information (dimming, on / off control, etc.). For example, if the sidewall 104 is equipped with several light sources, such as light from below the light source passing through as part of the circuit system 206 or a translucent / transparent material, the light source can be controlled to indicate detected or waiting user input to the user by, for example, by selecting a sequence such as immediately rotating the light (e.g., activating one light source / indicator sequence at a time by a spatial sequence indicating the sliding of a waiting / detected finger).

[0061] Item 207 relates to at least one possible connecting element, such as a conductive pin, rod, or wire, extending between different sides of the filling layer 207 and, for example, a circuit system 206 disposed on each of the sides. The provided connection may be wireless, either alternatively or additionally.

[0062] Object 150 is a point sketch illustrating user input that can be appropriately given and detected by the structure according to various embodiments of the present invention. In addition to light touches and 2D swiping activities, continuous gestures such as swiping on surfaces such as sidewall 104 can be detected and associated with predetermined responses. As covered above, since the UI solutions proposed herein form part of a larger collective of structures and / or devices, considering, for example, electronics in a vehicle, UI input detected by or via the multi-layered structure, or related responses involving, for example, control actions provided by at least functionally connected external devices or so-called host devices, other than or replacing the multi-layered structure itself, can be indicated.

[0063] In various embodiments, the multi-sided knob shape defined by the protrusion 101 or substantially by the protrusion 101 itself includes a top 201, a cross-section and / or a 2D projection, at least one of which preferably has a substantially rounded shape.

[0064] In the above and other embodiments, the protrusions and multilayer structures are generally configured to be preferably used for touch-based gesture detection by using the circuit system 206 via at least two of the plurality of sidewalls of the protrusion 101, preferably each sidewall, via direct wall mounting / providing (e.g., stacked printing) and / or remote positioning of sensing elements, such as electrodes and associated additional circuit system 206 of the multilayer structure.

[0065] In various embodiments, the multi-sided knob shape or groove shape defined by the protrusions in the multi-layer structure may include a general shape of a spherical cube (spherical cube) or a square-round ellipsoid. For example, the general or primary shape may be modified to have inclined and / or curved sidewalls 104 and / or a flat, angled or curved top 201.

[0066] In various embodiments, the multi-sided knob shape defined by the protrusion may include, for example, any one of 3, 4, 5, 6, 7 or 8 touch-sensitive sidewalls among a plurality of sidewalls.

[0067] Preferably, the knob or recess shape has rounded corners between at least two, preferably, adjacent sidewalls 104, and, where appropriate, the transition between the sidewalls 104 and the top 201 is also rounded. From the point of view of the materials and processes used (e.g., thermoforming or other 3D molding), a circular (rounded) shape may be preferred, achievable, and therefore more practical.

[0068] In various embodiments, at least one of the plurality of sidewalls 104 preferably defines a curved surface, which may be a raised surface and / or a recessed surface in the lateral L and / or transverse T directions of the sidewall.

[0069] In Figure 3, an embodiment of the multi-layer structure is illustrated at 300, and specifically, an associated knob-defined protrusion including a recessed sidewall is illustrated.

[0070] In Figure 4, an embodiment of the multi-layer structure is illustrated at 400, and specifically, an associated knob defining a protrusion including a raised sidewall is illustrated.

[0071] Preferably, at least one sidewall defines a substantially saddle surface, which is preferably convex in the lateral (L) direction of the sidewall and concave in the transverse (T) direction of the sidewall, or vice versa.

[0072] Figure 5 illustrates an embodiment of the multi-layer structure at 500, and specifically illustrates an associated knob-defined protrusion comprising a saddle surface-type sidewall (recessed in the lateral direction and convex in the transverse direction).

[0073] Figure 6 illustrates another embodiment of the multilayer structure at 500, and specifically illustrates an associated knob-defined protrusion comprising a saddle surface-type sidewall (protruding in the lateral direction and recessed in the transverse direction).

[0074] In various embodiments, the protrusion 101 may have a substantially flat or curved top 201, which may be substantially square-shaped, with a diameter of about 8 cm or less, more preferably about 7 cm or less, and most preferably on the order of about 4 to about 7 cm. Other sizes may also be used in some other embodiments.

[0075] Depending on the embodiment, the top 201 may be a single unit with any or more of the sidewalls 104, as shown, for example, in FIG2, or may have originally been a separate piece of different materials, and attached or formed on the protrusion wall defined by, for example, adhesives and / or suitable mechanical fastening elements (screws, bolts / nuts, snap fasteners, etc.).

[0076] In some embodiments, the top 201 (or the layer 203 above it) may implement a touch-sensitive surface (e.g., "button" functionality) for example by means of a lower capacitive sensing electrode and an associated other circuit system 206. In some embodiments, a touchpad or other functional user input features may be implemented similarly.

[0077] In various embodiments, the height of the protrusion may be, for example, about 4 cm or less, preferably between about 1 cm and 3 cm. Other sizes may also be used in some other embodiments.

[0078] In various embodiments, the length of one of the plurality of sidewalls in the lateral direction L is about 6 cm or less, preferably between about 3 and about 6 cm, and / or the length in the transverse direction T is about 4 cm or less, preferably between about 1 cm and 3 cm. Other dimensions may also be used in some other embodiments.

[0079] As will be understood by those skilled in the art and as mentioned above, the size can be adjusted for each embodiment based on, for example, a predicted usage scenario, including, for example, a user of a specific size (children and adults, with obvious differences in the size of their finger extensions) and the type of input to be registered via the UI. In some embodiments, the size can be selected (scaled up) to support, for example, users wearing different jewelry.

[0080] As covered above, the multi-layered structure including the electronic components and the knob shape formed by the protrusions can be configured to detect several different gestures, preferably selected from at least one touch type of the group consisting of: radial swipe (continuously rounding corners), lateral swipe, tap or multiple taps within a selected time period as appropriate, and / or continuous taps, pinch, outward expansion, parallel gestures such as swipes involving at least two fingers as appropriate, and relative gestures such as swipes involving at least two fingers as appropriate.

[0081] The detection or mapping logic may have been encoded in the circuit system 206 or at least functionally (e.g., via connector 230a) to external electronics connected to the circuit 206. For example, if several adjacent or otherwise configured touch sensing elements (such as capacitive electrodes) indicate a touch in a time sequence, this can be translated into a (continuous) swipe input detected by the detection logic, and then trigger an associated, linked control action that may potentially activate or deactivate a function of the subject or connected external device or system in response. Generally, the association between a particular type of touch (e.g., lateral swipe, tap, sequence of different actions, etc.) and the control action can be content-sensitive in a variety of ways. The association may, for example, have been configured as an application or application-specific view, and / or may depend on several other conditions, such as sensors or other measurable or settable values ​​(acceleration, rate or speed, temperature, pressure, illumination, orientation, time, position, etc.). However, for example, if a vibration motor or other vibration element is provided as part of the circuit system 206 in the multilayer structure, feedback can be provided by the multilayer structure itself in relation to the detected input and, where appropriate, indicative of the type of input identified, such as visual feedback and / or tactile feedback, such as illumination.

[0082] As previously mentioned herein, the multi-layered structure may include several light sources, such as LEDs. These light sources may be configured to have illumination functions based on, for example, decorative or informational (indicative) dynamics; for example, these light sources may be configured to illuminate, for example, the environment of the structure and / or the surfaces or other elements of the structure itself, such as the sidewall 104 or part of the top 201, which are considered ready or unready to receive input. Decorative shapes or graphics (paint, ink, surface undulations, masking, masking patterns, and translucent / transparent materials, etc.) disposed in the structure may also be illuminated. Additionally or alternatively, the light sources may be configured to further indicate detected touches via multi-sided 3D knobs or recessed shapes defined by protrusions, and, as appropriate, also indicate the location and / or nature of the detected touches.

[0083] In various embodiments, the control actions covered herein may include at least one action selected from the group consisting of: triggering of control signals, light control, light control in a multi-layer structure, external light control, vehicle feature control, main device feature control, air conditioning control, chassis control, multimedia control, window control, menu feature access, cursor movement, feature selection, feature activation, menu feature selection, scrolling action, menu item scrolling action, and zooming.

[0084] In some embodiments, the multilayer structure can be configured to better detect at least partially contactless 2D or 3D gestures on multiple knobs or recessed shapes, and further preferably to detect the type of gesture. For example, capacitive sensing can also be used for this purpose.

[0085] As also implied above, in various embodiments, taking into account predefined wavelengths in, for example, the visible spectrum, any of the different materials and / or other layers or elements of the substrate film 202 (such as filler 208, layer 203, or another film 212) may be at least partially substantially optically opaque or at least translucent (if not substantially transparent). Where applicable, at least a portion of the exterior (surface) of the multilayer structure, or at least the relevant elements that are visible or otherwise perceptible thereto, may be equipped with several visually distinguishable, decorative / aesthetic, and / or informational features, such as graphic patterns and / or colors thereon or therein. The materials used may be at least partially (i.e., at least in some locations) substantially optically transparent to radiation (such as visible light emitted by electronics thereon). For example, the transmittance may be about 80%, 85%, 90%, 95%, or higher.

[0086] In various embodiments, selected features, including, for example, graphics, coloring, or other visual features, may also be provided on the inner surface or any of the layers of the multilayer structure. Therefore, various impacts, frictions, chemicals, etc., that can easily damage, for example, painted, printed, or mounted surface features, do not affect or reach embedded / non-surface and potentially hermetically sealed features.

[0087] Figure 7 illustrates an embodiment of the multi-layer structure at 700, and specifically illustrates an associated knob-defined protrusion having a regular, highly symmetrical shape and defining six sidewalls. In other feasible embodiments, the number of sidewalls may be different, but the structure remains regular.

[0088] Figure 8 illustrates an embodiment of the multi-layer structure at 800, and specifically illustrates an associated knob-defined protrusion having a more irregular shape and defining five sidewalls. In other feasible embodiments, the number of sidewalls may naturally vary, while the shape remains generally irregular.

[0089] Figure 9 illustrates at 900 an embodiment of a main body device, such as a handrail, that includes a multi-layered structure (such as the embodiments of Figures 1 and 2).

[0090] Figure 10 includes a flowchart of an embodiment of the method according to the present invention at 1000.

[0091] At the start of the method for manufacturing a multilayer structure, a startup phase 1002 may be performed. During startup, necessary tasks such as material, component, and tool selection, acquisition, calibration, and other configuration tasks may be performed. Special attention must be paid to the fact that the selection of individual components and materials works together and undergoes a selected manufacturing and assembly process, which is preferably based on manufacturing process specifications and component data sheets or pre-checked through prototypes produced, for example, through investigation and testing. Therefore, equipment used such as molding / in-mold decoration (IMD), lamination, bonding, (thermo) forming, electronic device assembly, cutting, drilling, and / or printing equipment, as well as others, can be brought to operational status at this phase.

[0092] At 1004, at least one, optionally flexible, substrate film is obtained for housing, for example, a plastic or other material, such as an electronic device. The substrate film may initially be substantially flat or, for example, curved. The substrate film may be at least primarily a substantially electrically insulating material. Ready-made components, such as rolls or sheets of plastic film, may be obtained for use as substrate material. In some embodiments, the substrate film itself may be initially molded from a selected starting material using a mold and / or molding apparatus or other methods. Depending on the circumstances, the substrate film may be further processed at this stage. For example, it may be equipped with holes, notches, grooves, cuts, etc.

[0093] At 1006, preferably by means of one or more stacking techniques of printed electronics, a plurality of conductive elements defining, for example, wires (traces), sensing elements such as electrodes, and / or contact areas for constructing circuit designs are disposed on one or more of the included substrate films, on one or both sides thereof. For example, screen printing, inkjet printing, flexographic printing, gravure printing, or offset printing can be used, suitable for printing apparatus or apparatus applications. In some cases, subtractive or semi-additive processes may also be used. Further operations of thin film cultivation can be performed here, such operations involving, for example, printing or substantially providing graphics, visual indicators, optical elements, etc. thereon.

[0094] In various embodiments, the conductive element may include at least one material selected from the group consisting of: conductive ink, conductive nanoparticle ink, copper, steel, iron, tin, aluminum, silver, gold, platinum, conductive adhesive, carbon fiber, alloy, silver alloy, zinc, brass, titanium, solder, and any component. The conductive material used is optically opaque, translucent, and / or transparent at the desired wavelength, such as visible light, so as to, for example, block radiation such as visible light or allow radiation to be reflected from it, absorbed therein, or allowed to pass through.

[0095] At 1008, one or more typically off-the-shelf components, including various SMD electronic components, can be attached to a contact area on the thin film, for example, by means of solder and / or adhesive. Suitable pick-and-place or other mounting devices may be used for this purpose, for example. Alternatively or additionally, printed electronics techniques may be applied to virtually fabricate at least a portion of components, such as OLEDs, directly onto any or more of the included thin films. Therefore, as those skilled in the art will understand, the execution of items 1006 and 1008 for providing a multilayer structure having the desired circuit system may overlap in time. However, the mounted components may include, for example, one or more connectors.

[0096] For the sake of completeness, considering the provision of circuit systems and components to the structure, item 1009 refers to the possible attachment of one or more subsystems or 'sub-assemblies' that may be incorporated into an initial separate secondary substrate equipped with electronic devices such as ICs and / or various components. At least a portion of the electronic devices in a multilayer structure may be provided to the substrate film via such sub-assemblies. Where appropriate, the sub-assembly may be at least partially molded by a protective plastic layer before attachment to the main substrate. This may be, for example, the case of the component-sample IMSE node mentioned above. For example, adhesives, pressure, and / or heat may be used to mechanically bond the sub-assembly to the main (body) substrate. Solder, wiring, and conductive ink are examples of suitable options for providing electrical connections between the components of the sub-assembly and the remaining electrical components on the main substrate. Item 1009 may also be implemented, for example, in items 1006 or 10110. The locations shown are merely illustrative.

[0097] In some embodiments, before or after molding stage 1012, the substrate film preferably already contains at least a portion of, for example, a circuit design, such as (printed) conductive elements and, where applicable, electronic components, and / or at least a portion of connectors (see the double-curved arrows highlighting the fact that molding may alternatively or additionally occur between items 1006 and 1008 or even before item 1006). 1010 can be formed using thermoforming or cold forming, for example, to exhibit a desired shape, such as at least a partially three-dimensional (substantially uneven) shape, including the knobs or recesses defining protrusions discussed in more detail below. Suitable forming apparatuses, such as thermoforming machines, can be naturally used for this purpose. Alternatively or additionally, at least some forming can be performed after molding if a multilayer stack design has been established to undergo such processes.

[0098] At 1012, at least one plastic filler layer, preferably a thermoplastic or thermosetting layer, is formed on the substrate, preferably such as by injection molding, so as to preferably at least partially fill the volume defined by the shape of the protrusion (more applicable to the knob embodiment), and at least partially embed the circuit system and, where applicable, other components or elements of the multilayer structure (applicable to both the knob and recess embodiments). The molding material may be provided using several molding steps or by injection or via a single step, wherein the molding material may flow from one side of the film to the opposite side, even if, where appropriate, for example, through holes formed therein or by penetrating the substrate material itself (e.g., via thinned / thinner portions). The molding material may be, for example, substantially electrically insulating.

[0099] In practice, at least one substrate film equipped with several other features (such as circuitry) can be used as an insert in an injection molding process using at least one molding machine. When using two films, both films can be inserted into their own half-molds so that a plastic layer is injected at least therebetween. Alternatively, the second film can subsequently be attached to the aggregate of the first film and the plastic layer using a suitable lamination technique.

[0100] The final total thickness of the resulting stacked multilayer structure (excluding the protrusion dimensions discussed elsewhere herein) depends, for example, on the materials used to provide the necessary strength for manufacturing and subsequent use, and the associated minimum material thickness. Such cases must be considered on an example-by-example basis. For instance, the total thickness of the structure may be on the order of a few millimeters, but significantly thicker or thinner embodiments are also possible.

[0101] Item 1014 refers to possible additional tasks, such as post-processing tasks. Additional layers or generally characteristic features can be added to the multilayer structure by molding, lamination, or a suitable coating (e.g., deposition) process. These layers may have protective, indicative, and / or aesthetic values ​​(graphics, colors, patterns, text, digital data, etc.) as alternatives to or supplements to other plastics, and may contain materials such as fabric, leather, or rubber. Additional components, such as electronic devices, may be mounted on the outer surface of the structure, such as the outer surface of the substrate or on a molded layer thereon, depending on the embodiment. Shaping / cutting is possible. If equipped with connectors, the connectors can be connected to desired external connection elements, such as external connectors for external devices, systems, or structures (e.g., host devices). For example, two such connectors may together form a plug-and-receptacle type connection and interface.

[0102] At position 1016, the method execution ends.

[0103] In the embodiment 1100 depicted in FIG11, the protrusion 101 formed in the thin film 202 has been substantially flipped 180 degrees from the protrusion in the previously processed embodiment, and is thus configured to protrude away from the environment and users (fingers, styluses, etc.) of the multilayer structure, and thus differs from the previous embodiment in which the protrusion was substantially directed towards the environment and protruded away from the surrounding remaining substrate film and the overall multilayer structure, facing towards the interior of the multilayer structure. Here, the protrusion 101 of the thin film 202 therefore still defines a groove in the multilayer structure with vertical or inclined sidewalls, instead of an outwardly protruding knob shape. Even if there are other layers 203 such as films, coatings and / or fillers on the top of the formed groove, the groove will still preferably remain accessible and exist on the outer surface of the overall structure. The top 201 of the protrusion formed in the thin film 201 can therefore simultaneously define the bottom 1101 of the groove defined by the protrusion 101 relative to the overall multilayer structure. The size can be selected to allow sufficient space for the user's fingers to enter the groove for user input, for example, by using a light touch / or swipe to the touch wall 104 or the bottom 1101.

[0104] In this embodiment and similar embodiments, the volume defined or limited by the plane of the surrounding substrate film portion and the actual protrusion shape 101, thereby limiting the aforementioned groove that a user enters and interacts with using their fingers and typically primarily fingertips or styluses, may not (although it may) accommodate additional components such as electronic devices 206, which can be conveniently configured on the second side 202b of the film 202 in many situations, as shown in the figures, for example, substantially adjacent to (e.g., above and / or below) and / or away from the groove shape. Therefore, the sidewalls and the bottom of the groove facing and limiting the volume on the first side 202a of the film 201 may be free of other components when needed. In many real-world applications, the volume defined by the groove is typically contained by a fluid in the environment (such as air), and occasionally subsequently replaced by the user's fingers or stylus.

[0105] In general, the embodiments and features (materials, dimensions, shapes including protrusion shapes and sidewall shapes, additional elements, functionality, etc.) provided above, as well as various considerations and comments on the different general principles of the invention, can be adapted with necessary changes to the embodiments of FIG11, as will be understood by those skilled in the art.

[0106] In some embodiments, even combinations of outward (knob) and inward (groove) shapes can be provided in a multilayer structure and, where appropriate, in the same substrate film. For example, a larger groove shape may even integrate a smaller knob shape, or a larger knob shape may include a smaller groove shape, or such shapes may be positioned adjacent to each other.

[0107] Figure 12 illustrates an embodiment of the substrate film of Figure 11 via a related stereoscopic orthographic sketch at 1200. The created groove may have a shape different from the corresponding knob shape covered above. For example, another substantially similar but inverted shape may be used. The situation described herein is only an example of a possible scenario.

[0108] FIG13 illustrates an embodiment of the multilayer structure from the viewpoint of the potential overall shape, particularly in the region of the protrusion 101 of the substrate film 202, at 1300. FIG14 shows a sketch of a cross-sectional side view of the embodiment of FIG13 along line AA at 1400.

[0109] In the illustrated embodiment, the protrusion 101 protrudes from and extends outward from the surrounding remaining structure, i.e., toward the user in the usage environment, thereby establishing a knob shape therein, as discussed above with reference to various other embodiments, and several other material layers of the structure are also configured to generally follow the shape of the protrusion. One can thus identify the similar knob shape created by the filler 208 and, where applicable, by other layers in the structure such as the film 212 (if present). The total thickness of the actual material layers of the structure can thus be conveniently configured to remain substantially constant even at the location of the protrusion 101, as explained.

[0110] Figure 15 illustrates an embodiment of the multilayer structure from the viewpoint of the potential overall shape of the multilayer structure at 1500, particularly in the region where the recess of the substrate film 202 defines the protrusion 101. Therefore, the multilayer structure protrudes inward and away from the user and the environment in which the structure is used, wherein the other material layers of the structure generally follow the shape of the protrusion as well. Figure 16 illustrates the embodiment of Figure 15 via a cross-sectional side view along line AA at 1600.

[0111] Therefore, in the embodiments of Figures 13-14 and 15-16, for one or more adjacent and subsequent material layers, the overall multilayer structure is configured to generally follow the substantially undulating shape of the substrate film 202 at the location of the knob or groove-type protrusion 101 established therefrom. Thus, if necessary, a practically constant total thickness of the structure jointly established by the included material layers can be obtained. Still with respect to the overall multilayer structure, the protrusion on one side of the overall structure can be configured to be accompanied by a groove on the opposite side.

[0112] This method differs from the embodiments of Figures 2 and 11 previously discussed, for example, in which one or more other layers of the multilayer structure (e.g., filler 208 or film 212) do not at least substantially (on both sides) follow the shape of the substrate 202 at the location of the protrusion 101. In fact, the layers are essentially configured to have substantially planar surfaces at least opposite the surface facing the protrusion 101 (see, for example, the bottom surfaces of layers 208, 210, 212 in the relevant Figures 2 and 11), even if other potentially more complex non-planar layers and surface shapes are also feasible, as will be understood by those skilled in the art.

[0113] Furthermore, the content stated above regarding other embodiments including those illustrated in Figures 1 to 12 is also applicable to the embodiments in Figures 13 to 16, as will be readily understood by those skilled in the art.

[0114] The scope of this invention is determined by the appended claims together with their equivalents. Those skilled in the art will understand that the disclosed embodiments are constructed for illustrative purposes only, and other configurations applying many of the above principles can also be readily prepared to best suit various potential use cases. [Simplified Explanation of the Diagram]

[0028] Some embodiments of the invention are illustrated in the accompanying drawings by way of example rather than as a limitation.

[0029] Figure 1 illustrates an embodiment of the multilayer structure according to the present invention.

[0030] FIG2 illustrates a cross-sectional side view of a multilayer structure according to various embodiments of the present invention, such as the embodiment along line AA in FIG1.

[0031] Figure 3 illustrates an embodiment of the multi-layer structure, and specifically illustrates an associated knob-defined protrusion including a recessed sidewall.

[0032] Figure 4 illustrates an embodiment of the multi-layer structure, and specifically illustrates that the associated knobs including the protruding sidewalls define the protrusions.

[0033] Figure 5 illustrates an embodiment of the multi-layer structure, and specifically illustrates the associated knob-defined protrusion including a saddle surface-type sidewall.

[0034] Figure 6 illustrates another embodiment of the multi-layer structure, and specifically illustrates an associated knob-defined protrusion including a saddle surface-type sidewall.

[0035] Figure 7 illustrates an embodiment of the multi-layer structure, and specifically illustrates an associated knob defining a protrusion having a regular shape that defines six sidewalls.

[0036] Figure 8 illustrates an embodiment of the multi-layer structure, and specifically illustrates an associated knob defining a protrusion having an irregular shape that defines five sidewalls.

[0037] Figure 9 illustrates an embodiment of a main device including a multi-layer structure, such as a handrail.

[0038] Figure 10 is a flowchart of an embodiment of the method according to the present invention.

[0039] FIG11 illustrates another embodiment of the multilayer structure of the present invention via a cross-sectional side view, and specifically illustrates the associated groove defining the protrusion.

[0040] FIG12 illustrates an embodiment of the substrate film of FIG11 via a related stereoscopic orthographic projection sketch.

[0041] Figure 13 illustrates an embodiment of a multilayer structure from the perspective of the potential overall shape of the multilayer structure, particularly in the region of a protrusion of a substrate film that extends outward (i.e., toward the user) from the surrounding remaining structure and forms a knob, wherein the other material layers of the structure at least partially and generally follow the shape of the protrusion.

[0042] Figure 14 is a sketch of a cross-sectional side view of the embodiment along line AA in Figure 13.

[0043] Figure 15 illustrates an embodiment of a multilayer structure from the perspective of the potential overall shape of the multilayer structure, particularly in the region of a protrusion defined by a groove in a substrate film that protrudes inward from and away from the user and the structure's usage environment, wherein other material layers of the structure at least partially and generally follow the shape of the protrusion.

[0044] Figure 16 illustrates the embodiment of Figure 15 via a cross-sectional side view along line AA.

Claims

1. An integrated functional multilayer structure (100, 200, 300, 400, 500, 600, 700, 800, 1100, 1200, 1300, 1400, 1500, 1600) for constructing a gesture user interface (UI), comprising a flexible, 3D-formable substrate film (202), comprising a first surface (202a) facing an environment of the multilayer structure and a user therein, and a phase facing the interior of the multilayer structure. For the second surface (202b), wherein the remaining material of the first surface (202a) and the second surface (202b) and the substrate film (202) therebetween is partially defined as a three-dimensional protrusion (101) extending from a plane (220) of the surrounding substrate film material and formed by the partial stretching and molding of the substrate film (202), the protrusion (101) including a plurality of substantially vertical or inclined and, where appropriate, at least partially curved sidewalls (104) that can be sensed by touch. A circuit system (206) disposed on the substrate film (202) includes a plurality of conductive traces, electrodes and / or components configured to detect touches on the top (201) of two or more of the plurality of sidewalls (104) and preferably on the top (201) of one of the protrusions (101); and preferably at least one filler layer (208) of thermoplastic filler material configured to be molded or cast onto the substrate film (202) as appropriate to at least partially embed the circuit system (206), wherein at least one of the plurality of sidewalls, in particular each of the plurality of sidewalls, defines a curved surface in the lateral (L) direction and / or transverse (T) direction of the sidewalls.

2. The structure of claim 1, wherein the circuit system (206) is at least partially housed by a volume (V) defined by the shape of the protrusion and the plane.

3. The structure of claim 1 or 2, wherein the at least one filling layer (208) at least partially fills the volume (V) defined by the shape of the protrusion and the plane.

4. The structure of claim 1 or 2, wherein (100, 200) the protrusion (101) defines a preferred continuous, multi-sided knob extending outward from the surrounding multi-layered structure.

5. The structure of claim 1 or 2, wherein the protrusion (101) includes a top (201) having a substantially square or round shape, a cross section and / or a 2D projection.

6. The structure of claim 1 or 2, wherein (1100, 1200) the protrusion (101) defines a preferred continuous, multi-sided groove in the multilayer structure, the bottom (1101) of the multilayer structure being preferably established by the top (201) of the protrusion (101).

7. The structure of claim 1 or 2, wherein the protrusion comprises a general shape of a spherical cube or a round ellipsoid modified as appropriate by inclined and / or curved sidewalls and / or a plane, an angled or curved top (201).

8. The structure of claim 1 or 2, wherein the protrusion includes 3, 4, 5, 6, 7 or 8 touch-sensitive sidewalls of the plurality of sidewalls (104), preferably having rounded corners between at least two, preferably each adjacent sidewall, and, where appropriate, the transition between the sidewall and the top (201, 1101) of one of the protrusions is also rounded.

9. The structure of claim 1, wherein the at least one sidewall substantially defines a saddle surface, the saddle surface preferably being raised in the lateral (L) direction and recessed in the transverse (T) direction of the sidewall, or vice versa.

10. The structure of claim 1 or 2, wherein the protrusion has a substantially flat or curved top (201) which, where applicable, has a substantially rounded shape and a diameter of approximately 8 cm or less, more preferably approximately 7 cm or less, and most preferably on the order of approximately 4 to approximately 7 cm.

11. The structure of claim 1 or 2, wherein the height of the protrusion is about 4 cm or less, preferably between about 1 cm and 3 cm.

12. The structure of claim 1 or 2, wherein the length of the plurality of sidewalls in the lateral direction (L) is about 6 cm or less, preferably between about 3 and about 6 cm, and / or the length in the transverse direction (T) is about 4 cm or less, preferably between about 1 cm and 3 cm.

13. The structure of claim 1 or 2, comprising at least one material layer (203), wherein the at least one material layer comprises a coating or a film on the first surface (202a) of the substrate film (202), wherein the material of the material layer is preferably different from the material in the substrate film (202).

14. The structure of claim 1 or 2, comprising another thin film (212) on the side of the filler layer (208) opposite to one side of the substrate thin film (202), the other thin film (212) being configured, as appropriate, to accommodate at least a portion of the circuit system (206).

15. The structure of claim 1 or 2, wherein the substrate film and / or another film or material layer comprises at least one material selected from the group consisting of: polymers, thermoplastic materials, electrically insulating materials, polymethyl methacrylate (PMMA), polycarbonate (PC), copolyester, copolyester resin, polyimide, copolymer of methyl methacrylate and styrene (MS resin), glass, polyethylene terephthalate (PET), carbon fiber, organic materials, biomaterials, leather, wood, textiles, fabrics, metals, organic natural materials, solid wood, veneer, plywood, stem bark, bark, birch bark, cork, natural leather, natural textiles or fabric materials, naturally grown materials, cotton, wool, flax, silk, and any combination thereof.

16. The structure of claim 1 or 2, wherein the at least one filler layer comprises at least one material selected from the group consisting of: polymers, organic materials, biomaterials, composite materials, thermoplastic materials, thermosetting materials, elastic resins, PC, PMMA, ABS, PET, copolyesters, copolyester resins, nylon (PA, polyamide), polypropylene (PP), thermoplastic polyurethane (TPU), polystyrene (GPPS), thermoplastic silicone vulcanizate (TPSiV), and MS resin.

17. The structure of claim 1 or 2, wherein the circuit system (206) includes or the remaining structure includes at least one component selected from the group consisting of: electronic components, electromechanical components, electro-optical components, radiative emission components, light-emitting components, light-emitting diodes (LEDs), organic LEDs (OLEDs), side-emitting LEDs or other light sources, top-emitting LEDs or other light sources, bottom-emitting LEDs or other light sources, radiation detection components, light detection or photosensitive components, photodiodes, photoelectric crystals, photovoltaic devices, sensors, micromechanical components, switches, touch switches, touch panels, proximity switches, touch sensors, atmospheric sensors, temperature sensors, pressure sensors, humidity sensors, gas sensors, proximity sensors, capacitive switches, capacitive sensors Sensors, projected capacitive sensors or switches, single-electrode capacitive switches or sensors, capacitive pushbuttons, multi-electrode capacitive switches or sensors, self-capacitive sensors, mutual-capacitive sensors, inductive sensors, sensor electrodes, micromechanical components, UI elements, user input elements, vibration elements, sound generating elements, communication elements, transmitters, receivers, transceivers, antennas, infrared (IR) receivers or transmitters, wireless communication elements, wireless tags, radio tags, tag readers, data processing elements, microprocessors, microcontrollers, digital signal processors, signal processors, programmable logic chips, application-specific integrated circuits (ASICs), data storage elements, electronic device subassemblies, light guiding elements, light guides, lenses, and reflectors.

18. The structure of request item 1 or 2 is configured to detect at least one touch type selected from the group consisting of: radial swipe, lateral swipe, tap, multiple taps within a selected time period and / or between consecutive taps, pinch, spread, parallel gestures such as swipes involving at least two fingers, and relative gestures such as swipes involving at least two fingers.

19. As in request 1 or 2, the structure is configured to perform a selected control action in response to a detected touch, the control action being associated with a type identified by the touch via mapping logic or data.

20. The structure of claim 19, wherein the control action includes at least one action selected from the group consisting of: triggering of a control signal, light control, vehicle feature control, main unit feature control, air conditioning control, chassis control, multimedia control, home appliance control, window control, menu feature access, cursor movement, feature selection, feature activation, menu feature selection, scrolling action, menu item scrolling action, and zooming.

21. The structure of claim 1 or 2, comprising several light sources, such as LEDs, preferably configured to indicate the detected touch and, where appropriate, the nature of the detected touch, further, where appropriate, by a multi-sided knob or recess shape defined by the protrusion.

22. The structure of request 1 or 2 is configured to better detect at least partially contactless 2D or 3D gestures on the protrusion, and further preferably to detect the type of the gesture.

23. A main device (900) comprising the structure of any of the preceding claims, which may include at least one of a console, a vehicle console, a door, a top panel, a multimedia device, a home appliance, a personal communication device, or a control device.

24. The main device of claim 23 includes an armrest equipped with an arm or wrist sensor, such as a capacitive, resistive, optical, and / or pressure sensor, and configured to change the operability of the structure based on data provided by the sensor, and to adjust or activate touch sensing in response to the detection of the presence of a user's arm or wrist on the armrest.

25. A method (1000) for manufacturing an integrated multilayer structure, comprising: obtaining a substrate film (1004) comprising a formable, optionally thermoformable material and further comprising a first surface (202a) facing an environment of the structure and a user therein and an opposing second surface (202b) facing the interior of the structure; preferably providing a circuit system on the substrate film using printed electronics technology and / or selected mounting technology (1006, 1008); 3D forming the substrate film (1010) such that the first surface (202a) and the second surface (202b) and the remaining material of the substrate film (202) formed therebetween partially define a three-dimensional (3D) protrusion (204) extending from a plane (220) of the surrounding substrate film material, the protrusion (204) comprising a plurality of substantially vertical or inclined and optionally at least partially curved sidewalls (204) perceptible by touch. The circuit system includes a plurality of conductive traces, electrodes and / or components configured on the substrate film for detecting touches on the top (201) of one of the plurality of sidewalls and preferably on the top of one of the protrusions, and wherein at least one of the plurality of sidewalls, in particular each of the plurality of sidewalls, defines a curved surface in the lateral (L) direction and / or transverse (T) direction of the sidewalls; and, where appropriate, at least one filler layer (1012) of preferably thermoplastic filler material disposed on the substrate film by injection molding or casting to at least partially embed the circuit system and, where appropriate, a volume (V) defined by the shape of the protrusion and the plane, wherein the circuit system is at least partially accommodated by the volume.

26. The method of claim 25, wherein the protrusion includes a top (201) having a substantially square or circular shape, a cross section and / or a 2D projection.

27. The method of claim 25 or 26, wherein (100, 200) the protrusion (101) defines a preferred continuous, multi-sided knob (100, 200) extending outward from the surrounding multilayer structure.

28. The method of claim 25 or 26, wherein (1100, 1200) the protrusion (101) defines a preferred continuous, multi-sided groove in the multilayer structure, the bottom (1101) of the multilayer structure being preferably established by the top (201) of the protrusion (101).

Images