Airbag and switch assembly with one-piece cover

Abstract

An airbag and switch assembly for a vehicle includes an airbag and a one-piece airbag cover. The one-piece airbag cover includes an airbag deployment portion and a switch portion. The switch portion has a front surface and a rear surface with the front surface having an array of buttons zones. The airbag and switch assembly further includes a switch assembly. The switch assembly includes a flexible circuit having a first surface and a second surface wherein the first surface of the flexible circuit is coupled to the rear surface of the switch portion. An array of force sensors is disposed on the second surface of the flexible circuit, with each individual force sensor of the array of force sensors corresponding to an individual button zone of the array of button zones.

Description

AIRBAG AND SWITCH ASSEMBLY WITH ONE-PIECE COVERCross Reference To Related Applications

[0001] This application claims the benefit of U.S. Provisional Patent Application No.63 / 571,789 filed on March 29, 2024, the entire contents of which are incorporated herein by reference.Technical Reid

[0002] The present disclosure relates to safety devices for passenger vehicles. In particular, the disclosure relates to an airbag and switch assembly with a one-piece cover. Passenger vehicles may include, for example, automobiles, boats, trains, aircrafts, and spacecrafts.Background

[0003] Typical vehicle airbags and switches (e.g., buttons) are installed separately as independent assemblies. If located adjacent one another, gaps between them may lead to issues with aesthetics and with intrusion of foreign material. Mechanical switches that require a relatively large degree of motion to operate, such as those that move a conductive element into contact with another conductive element, may become inoperable if foreign material gets caught in between the elements. Also, the gaps may be uneven and inconsistent around and between the airbag and switches, typically resulting in customer complaints and warranty costs for replacement parts.

[0004] For example, most automobile steering wheels have airbags and switches installed on them, but design choices are constrained due to the need for separate airbag covers and switch assemblies. Typically, an automobile steering wheel will have a centrally located airbag and at least two switch assemblies, one on each lateral side of the airbag when the steering wheel is in its neutral position (i.e., automobile wheels pointed straight forward). As a result, a gap will be formed all around the perimeter of the airbag, typically in a circular or oval shape, leaving room for foreign material intrusion. Therefore, there is a need to produce an airbagand switch assembly with a one-piece cover that eliminates the typical gaps seen in modern vehicles.Summary

[0005] In some implementations, an airbag and switch assembly for a vehicle comprises an airbag and a one-piece cover. The one-piece cover comprises an airbag deployment portion and a switch portion, the switch portion comprising a front surface and a rear surface. The front surface comprises an array of buttons zones. The airbag and switch assembly further comprises a switch assembly, the switch assembly comprising a flexible circuit. The flexible circuit comprises a first surface and a second surface, the first surface being coupled to the rear surface of the switch portion. The switch assembly further comprises an array of force sensors disposed on the second surface, each individual force sensor of the array of force sensors corresponding to an individual button zone of the array of button zones.

[0006] In some implementations, the airbag and switch assembly further comprises at least one non-force sensor disposed adjacent to the rear surface of the switch portion, wherein the at least one non-force sensor is configured to confirm which individual button zone of the array of button zones is receiving an activation force imparted by a vehicle occupant. In some implementations, the non-force sensor comprises an infrared light source and an array of infrared light receivers, each of the infrared light receivers of the array of infrared light receivers corresponding to each of the individual button zones of the array of button zones. In some implementations, the infrared light source comprises an array of infrared light sources. In other implementations, the non-force sensor comprises a touch-based capacitive sensor.

[0007] In some implementations, the airbag deployment portion comprises a front surface and a rear surface. In some implementations, the switch assembly further comprises a hom sensor, wherein the horn sensor is coupled to the rear surface of the airbag deployment portion. In some implementations, the rear surface of the airbag deployment portion comprises an l-shaped tear seam. In other implementations, the rear surface of the airbag deployment portion comprises an H-shaped tear seam.

[0008] In some implementations, the rear surface of the switch portion comprises an array of activation zones and an array of walls, wherein each individual wall of the array of walls isdisposed between two adjacent activation zones of the array of activation zones. In some implementations, each individual activation zone corresponds to an individual button zone of the array of button zones.

[0009] In some implementations, the flexible circuit is coupled to a printed circuit board (PCB). In some implementations, the airbag and switch assembly further comprises a haptic actuator coupled to the PCB, the haptic actuator configured to deliver haptic energy to the switch portion. In some implementations, the haptic actuator is a coneless voice coil and magnet assembly.

[0010] In other implementations, the switch assembly further comprises a horn sensor, wherein the horn sensor is coupled to the PCB. In some implementations, the airbag deployment portion comprises a front surface and a rear surface, wherein the horn sensor is coupled to the rear surface of the airbag deployment portion.

[0011] In some implementations, the airbag and switch assembly further comprises a processor and a memory, the memory storing instructions for execution by the processor, wherein the instructions cause the processor to control a vehicle function in response to the activation force. In some implementations, each individual button zone of the array of button zones corresponds to a different vehicle function capable of being controlled by the processor.In some implementations, the switch assembly further comprises a printed circuit board (PCB), wherein the processor and the memory are coupled to the PCB. In other implementations, the processor and the memory are disposed in the vehicle spaced apart from the airbag and switch assembly.Brief Description of the Drawings

[0012] The drawings are merely exemplary to illustrate steps, structure, and certain features that can be used singularly or in combination with other features. The disclosure should not be limited to the implementations shown.

[0013] FIG. 1 is a perspective view of a steering wheel having an airbag and switch assembly with a one-piece cover.

[0014] FIG. 2 is perspective view of the one-piece cover of FIG. 1 from the front.

[0015] FIG. 3 is perspective view of the one-piece cover of FIG. 2 from the rear.

[0016] FIG.4 is a perspective view of a rear surface of a switch portion of the one-piece cover of FIG. 3.

[0017] FIG. 5 is a perspective view of the switch portion of FIG. 4 with a flexible circuit and force sensors.

[0018] FIG. 6 is a perspective view of the switch portion of FIG. 5 with a rigid printed circuit board (RGB).

[0019] FIG. 7 is a perspective view of the RGB of FIG. 6 coupled to the flexible circuit of FIG.5.

[0020] FIG. 8 is a perspective view of the switch portion of FIG. 6 along with a horn sensor connector, a vehicle connector, and a haptic plate.

[0021] FIG. 9 is a perspective view of the switch portion of FIG. 8 with a haptic actuator coupled to the haptic plate.

[0022] FIG. 10 is a perspective view of the switch portion of FIG. 9 with a switch cover and a haptic cover.

[0023] FIG. 11 is perspective view of the airbag and switch assembly of FIG. 1 showing an I- shaped tear seam.

[0024] FIG. 12 is perspective view of the airbag and switch assembly of FIG. 1 showing an Flshaped tear seam.

[0025] FIG. 13 is perspective view of the airbag and switch assembly of FIG. 1 showing an airbag module installed in an airbag chute.

[0026] FIG. 14 is a perspective view of the airbag and switch assembly of FIG. 13 with the airbag module removed.Detailed Description

[0027] The present disclosure relates to safety devices for passenger vehicles. The devices, assemblies, and systems disclosed herein provide for an airbag and switch assembly with a one-piece cover, eliminating any gaps between the airbag and the switches. In one example, the airbag and switch assembly is used in automobiles, including on a steering wheel. When used on a steering wheel, the airbag and switch assembly with one-piece cover provides for a consistent appearance while eliminating the risk of foreign material intrusion into theswitches. Alternatively, the airbag and switch assembly with one-piece cover can be used elsewhere in the automobile, such as in a dashboard.

[0028] As shown in FIGS. 1-3, an airbag and switch assembly 100 is installed on a steering wheel 101. A one-piece cover 103 comprises an airbag deployment portion 104, from which an airbag 102 (as shown in FIG. 13) can deploy adjacent a passenger of a vehicle, and a switch portion 108 on either side of the airbag deployment portion 104. The switch portion 108 comprises a front surface 109, as shown in FIG. 2, and a rear surface 110, as shown in FIG. 3.The switch portion 108 comprises an array of button indicators 112 on the front surface 109 indicating an array of button zones 111. Each button zone 111 encompasses one button indicator 112 and a corresponding light transmissive portion 113 (described below). A driver of the automobile, for example, may press on one of the button zones 111 to control a vehicle function, as greater described below, such as cruise control, audio system volume control, or autonomous driving activation, among other options depending on the vehicle environment.

[0029] In some implementations, the one-piece cover 103 may be formed by injection molding using plastic or other suitable material capable of being injection molded. In some implementations, the one-piece cover 103 is a dark, opaque color, such as black, accomplished by molding plastic to a black film during a film insert molding process. To create the button indicators 112 on the front surface 109, the film insert molding process may include other films, whereby the films have images of the button indicators 112 and may be integrally molded with the one-piece cover for durability and to provide a seamless, aesthetically pleasing design. In other implementations, the button indicators may be applied using adhesives or may be etched into the one-piece cover using a laser, for example, to create transparent / translucenf / colored portions in the black film. In other implementations, the one-piece cover may be any other color as desired, fully transparent / translucent, partially transparent / translucent, or include other images, logos, or trademarks.

[0030] Referring now to FIG. 4, the rear surface 110 of the switch portion 108 comprises an array of activation zones 115 and an array of walls 116. Each individual wall 116 of the array of walls 116 is disposed between two adjacent activation zones 115 of the array of activation zones 115. The walls 116 extend away from the rear surface 110 and may be integrally molded with the one-piece cover 103 or may be made separately from and coupled to the one-piece cover 103. The activation zones 115 may be formed as "thinned out" portions of the one- piece cover 103, whereby the activation zones 115 extend from the rear surface 110 towardsthe front surface 109. Alternatively, the activation zones 115 may not be thinned out. In either case, the walls 116 extend further away from the rear surface 110 than the activation zones 115, thereby forming a rigid barrier between each individual activation zone 115 of the array of activation zones 115.

[0031] As seen in FIGS. 5 and 7, a flexible circuit 120 comprises a first surface 121 and a second surface 122. The first surface 121 of the flexible circuit 120 is coupled to the rear surface 110 of the switch portion 108 using, for example, an adhesive 123. A portion of the flexible circuit 120 is coupled to the rear surface 110 within each individual activation zone 115 of the array of activation zones 115. The activation zones 115 may include locating posts117 to assist in aligning the flexible circuit 120 in the proper position within the activation zones 115. An array of force sensors 124 is disposed on the second surface 122 of the flexible circuit 120 with each individual force sensor 124 of the array of force sensors 124 being located within each individual activation zone 115 of the array of activation zones 115 and therefore each force sensor 124 corresponds to an individual button zone 111 of the array of button zones 111. The force sensors 124 can be any device or structure that can transform force into a signal. The signal can be, among others, electrical, electronic (digital or analog), mechanical, or optical. For example, in some implementation the force sensors 124 are microelectromechanical systems (MEMS) sensors. In one example, the MEMS sensors are structure-based piezo-resistive sensors.

[0032] The flexible circuit 120 comprises a connector 125 for electrically coupling the flexible circuit 120 to a rigid printed circuit board (RGB) 126 disposed adjacent the flexible circuit 120. In some implementations, at least one non-force sensor is disposed adjacent the rear surface110 of the switch portion 108, wherein the at least one non-force sensor is configured to confirm which individual button zone 111 of the array of button zones 111 is receiving an activation force imparted by a vehicle occupant. In some implementations, as shown in FIG.7, the at least one non-force sensor comprises an array of infrared light sources 127 and an array of infrared light receivers 128. Each of the infrared light sources 127 of the array of infrared light sources 127 and each of the infrared light receivers 128 of the array of infrared light receivers 128 correspond to each of the individual activation zones 115 of the array of activations zones 115 and therefore to each of the individual button zones 111 of the array of button zones 111. In other implementations, there is only one infrared light source whichfunctions (as discussed below) with all of the infrared light receivers of the array of infrared light receivers.

[0033] To confirm which individual button zone 111 of the array of button zones 111 is receiving the activation force imparted by the vehicle occupant, the one-piece cover 103 defines light transmissive portions 113 in each button zone 111 adjacent each button indicator112. The light transmissive portions 113 may be holes in the one-piece cover 103, may be formed by transparent / translucent material, or may be any other type of design that allows light to pass through the one-piece cover 103. When the vehicle occupant touches the one- piece cover at one of the button indicators 112, such as with a finger, the finger will change the absorptive / transmissive characteristics of infrared light coming from the infrared light source 127. The infrared light receiver 128 corresponding to the touched button indicator 112 will therefore read a change in the infrared light's absorptive / transmissive characteristics, confirming which button indicator 112 was touched by the vehicle occupant (i.e., in addition to the sensed force by the force sensors 124 as described below). Additionally, a visible light source 129 may be coupled to the PCB 126 in a similar manner to shine visible light through the light transmissive portions 113 to help the vehicle occupant locate the button zones 111 in low-light conditions.

[0034] In other implementations, a capacitive sensor 130, as shown in FIG. 2, may be embedded in or otherwise coupled to the one-piece cover 103 adjacent the button zones 111 to similarly detect which button zone 111 is being touched by the vehicle occupant. The capacitive sensor 130 is further electrically coupled to the PCB 126. The capacitive sensor 130 may comprises an array of capacitive sensors 130 adjacent each individual button zone 111 of the array of button zones 111 or may be one capacitive sensor 130 surrounding all of the button zones 111, so long as it is capable of determining where on the capacitive sensor 130 the vehicle occupant is touching.

[0035] Referring now to FIGS. 6 and 8-10, a haptic actuator 133 is coupled to the PCB 126 via a connector 134. In some implementations, the haptic actuator 133 may be a coneless voice coil and magnet assembly. In other implementations, the haptic actuator may be an eccentric rotating mass assembly or linear actuator assembly, for example. The haptic actuator 133 is configured to deliver haptic energy to the switch portion 108 through a haptic plate 131, typically a plastic plate for maximum haptic effect, that is coupled to haptic posts 119 via fasteners 132. Haptic posts 119 extend from the front surface 109 of the switch portion 108through openings in the RGB 126 so that the haptic plate 131 can be directly coupled to the one-piece cover 103. The haptic actuator 133 is coupled to the haptic plate 131 and therefore haptic energy can be passed from the haptic actuator 133 to the haptic plate 131 and from the haptic plate 131 to the one-piece cover 103 in the area of the switch portion 108 through the haptic posts 119. Therefore, a vehicle occupant operating the switch can feel the haptic energy and interpret that energy as confirmation the switch assembly has been activated. A haptic housing 135 may be installed around the haptic system during final assembly. Similarly, a switch housing 141 may be installed around the rest of the switch assembly to protect the various components, coupled by fasteners 132 inserted into housing fastener openings 118 which also extend from the front surface 109 of the switch portion 108. In some implementations, the haptic housing 135 and switch housing 141 are made from plastic. In other implementations, there is no haptic plate and the haptic actuator is coupled to the one- piece cover.

[0036] The airbag deployment portion 104 comprises a front surface 105 and a rear surface 106. Extending from the rear surface 106 of the airbag deployment portion 104 is an airbag chute 107 which houses the airbag 102 (as shown in FIG. 13). The airbag chute may be integrally formed with the one-piece cover 103 or be formed separately and coupled to the one-piece cover 103. A horn sensor 136 comprises a horn flexible circuit 137, a connector 138, and at least one force sensor 124 coupled to the horn flexible circuit 137. The hom sensor 136 is coupled to the rear surface 106 of the airbag deployment portion 104, for example by using an adhesive to couple the hom flexible circuit 137 to the rear surface 106. As best seen in FIG. 8, to connect the horn sensor 136 to the RGB 126, the horn flexible circuit137 extends through a horn circuit routing hole 139 formed in the airbag chute 107 and is coupled to the PCB 126 via the connector 138. As shown in FIGS. 11-12, the airbag and switch assembly 100 may comprise at least two horn sensors 136, each comprising at least once force sensor 124.

[0037] As shown in FIG. 2, the front surface 105 of the airbag deployment portion 104 comprises at least one horn indicator 114. In the implementations shown in the FIGURES, there are a total of four horn indicators 114 corresponding to four individual force sensors 124 of two horn sensors 136. In other implementations, there may be more or less hom indicators, horn sensors, and therefore force sensors. The one-piece cover 103 also defines light transmissive portions 113 adjacent each horn indicator 114, similar to the lighttransmissive portions 113 described above. The horn sensor 136 may therefore further comprise a visible light source 129 and / or an infrared light source 127 and infrared receiver128, similar as described above with respect to the switch assembly, to assist the vehicle occupant in finding the horn indicator 114 and to confirm the vehicle occupant is providing an activation force to an individual horn indicator 114. In some implementations, the haptic actuator 133 can be used to deliver haptic energy to the one-piece cover 103 to confirm the horn function has been activated. In other implementations, an additional haptic actuator may be coupled to the airbag deployment portion near the hom sensor.

[0038] To ensure proper deployment of the airbag 102 through the one-piece cover 103 during an emergency event, such as a vehicle collision, the rear surface 106 of the airbag deployment portion 104 may include a weakened portion, such as a tear seam which is known in the airbag art. As shown in FIG. 11, the tear seam 142 is referred to as an l-shaped tear seam, wherein the tear seam forms a capital I shape when the steering wheel 101 is in its neutral position. As a result, when the airbag 102 deploys from the assembly 100, "doors" open toward each switch portion 108 to allow the airbag to position itself between the steering wheel 101 and the vehicle occupant. Alternatively, as shown in FIG. 12, the tear seam142 is referred to as an H-shaped tear seam, wherein the tear seam forms a capital H shape when the steering wheel 101 is in its neutral position. As a result, when the airbag 102 deploys from the assembly 100, "doors" open toward the top and bottom of the steering wheel 101 to allow the airbag to position itself between the steering wheel 101 and the vehicle occupant.In both implementations, the horn sensors 136 are coupled to appropriate locations on the rear surface 106, as shown, to avoid interference with the tear seams 142 and airbag 102 deployment.

[0039] To assist with airbag 102 retention and with installation of the airbag and switch assembly 100 into the steering wheel 101, an airbag retainer 143 may be installed around the airbag chute 107. The airbag retainer 143 is typically formed from a piece of stamped metal, such as steel, but may be made from any suitable material such as plastic or aluminum, provided the appropriate structural properties are acquired. As shown in FIG. 14, the airbag retainer 143 defines steering wheel connector holes 146 to facilitate coupling the assembly100 to features (e.g., pins or hooks, not shown) on the steering wheel 101. The airbag chute 107 also defines protrusions 144 which can be inserted through holes in the airbag retainer143 to assist in manufacturing which can then be heat-staked to the steering wheel connectorholes 146 to further bolster the connection of the components to each other. The airbag retainer 143 may also include dampeners 145, such as rubber pads, to dampen noise and vibration with respect to the assembly 100 and the steering wheel 101.

[0040] To facilitate coupling of the airbag and switch assembly 100 to vehicle computers external of the assembly 100, a vehicle connector 140 is coupled to the PCB 126. To provide said coupling, an electrical wiring harness, not shown, plugs into the vehicle connector 140 on one end and into a vehicle computer on another end. The vehicle computer may be located anywhere within the vehicle. Additionally, in some implementations, the assembly 100 comprises a controller 147 having a processor 148 and a memory 149. The memory 149 stores software instructions for execution by the processor 148 to control the assembly 100. The controller 147, as shown in FIG. 8, may be directly coupled to the PCB 126. In other implementations, as shown in FIG. 9, the controller 147 may be installed outside of the assembly 100 elsewhere within the vehicle, including within a separate switch assembly, as represented by the dashed line. The connection between the assembly 100 and the controller147 may be carried through the vehicle connector 140 and its associated wiring harness, through a wireless signal, or through another wiring harness extending from the PCB 126 to the controller 147.

[0041] When a vehicle occupant presses on a button indicator 112, the button zone 111 corresponding to the pressed button indicator 112 receives an activation force that locally moves the one-piece cover 103 inward in the area of the button zone 111 (i.e., the front surface 109 of the switch portion 108 moves toward the PCB 126). In response, the force sensor 124 corresponding to that pressed button zone 111 is put under strain by the inward movement of the one-piece cover 103 and the force sensor 124 measures the strain and sends that measurement to the processor 148 to control a vehicle function in accordance with instructions stored on the memory 149. Simultaneously, the infrared light source 127 and infrared receiver 128 are controlled by the processor 148 to redundantly confirm which button zone 111 is receiving the activation force. Alternatively, the capacitive sensor 130 may confirm which button zone 111 is receiving the activation force. The processor 148 may also control the haptic actuator 133 to provide a haptic response to the vehicle occupant. The assembly100 works substantially the same way when a horn indicator 114 is provided with an activation force.

[0042] Because each individual button zone 111 of the array of button zones 111 correspond to an individual activation zone 115 of the array of activation zones 115, each force sensor 124 within each activation zone 115 corresponds to a single vehicle function. The walls 116 between each adjacent activation zone 115 provide rigidity to the one-piece cover 103 in the area of the walls 116, thus ensuring that when an activation force is imparted to an individual button zone 111, the corresponding force sensor 124 will receive the maximum amount of strain while the remaining force sensors 124 will receive little to no strain because the inward movement of the one-piece cover 103 is limited to the button zone 111 receiving the activation force. This structure helps to reduce noise in the force sensor 124 readings and prevent unintended activation of vehicle functions. For example, typical activation forces for switch assemblies in vehicle environments are less than or equal to 10 N which can create inward movement of the one-piece cover 103 of anywhere from a few microns to a few millimeters, depending on material choices and other characteristics, such as wall 116 thickness. In some implementations, the inward movement of the one-piece cover 103 caused by the activation force is limited to 5 microns or less. In other implementations, the inward movement is limited to 3 millimeters or less.

[0043] The processor 148 and memory 149 may be any type of processor and memory as known in the art that is suitable for vehicle use. In its most basic form, the controller 147 may include a processor 148 and a memory 149. The processor 148 may be a standard programmable processor that performs arithmetic and logic operations necessary for operation of the switch assembly. The processor 148 may be configured to execute program code encoded in tangible, computer-readable media. For example, the processor 148 may execute program code stored in the memory 149, which may be volatile or non-volatile memory. The memory 149 is only one example of tangible, computer-readable media. In one aspect, the controller 147 can be considered an integrated device such as firmware. Other examples of tangible, computer-readable media include DVDs, hard drives, flash memory, or any other machine-readable storage media, wherein when the program code is loaded into and executed by a machine, such as the processor 148, the machine becomes an apparatus for practicing the disclosed subject matter.

[0044] Any combination of one or more computer-readable medium(s) may be utilized. The computer-readable medium may be a computer-readable signal medium or a computer- readable storage medium. A computer-readable storage medium may be, for example, butnot limited to, an electronic, magnetic, optical, electromagnetic, infrared, or semiconductor system, apparatus, or device, or any suitable combination of the foregoing. More specific examples (a non-exhaustive list) of the computer-readable storage medium would include the following: an electrical connection having one or more wires, a portable computer diskette, a hard disk, a random access memory (RAM), a read-only memory (ROM), an erasable programmable read-only memory (EPROM or Flash memory), an optical fiber, a portable compact disc read-only memory (CD-ROM), an optical storage device, a magnetic storage device, or any suitable combination of the foregoing. In the context of this document, a computer-readable storage medium may be any tangible medium that can contain or store a program for use by or in connection with an instruction execution system, apparatus, or device.

Claims

CLAIMSWhat is claimed is:

1. An airbag and switch assembly for a vehicle comprising: an airbag; a one-piece cover comprisingan airbag deployment portion and a switch portion, the switch portion comprising a front surface and a rear surface, the front surface comprising an array of buttons zones; and a switch assembly, the switch assembly comprising: a flexible circuit comprising a first surface and a second surface, the first surface being coupled to the rear surface; and an array of force sensors disposed on the second surface, each individual force sensor of the array of force sensors corresponding to an individual button zone of the array of button zones.

2. The airbag and switch assembly of claim 1, further comprising at least one non-force sensor disposed adjacent to the rear surface, wherein the at least one non-force sensor is configured to confirm which individual button zone of the array of button zones is receiving an activation force imparted by a vehicle occupant.

3. The airbag and switch assembly of claim 2, wherein the at least one non-force sensor comprises an infrared light source and an array of infrared light receivers, each of the infrared light receivers of the array of infrared light receivers corresponding to each of the individual button zones of the array of button zones.

4. The airbag and switch assembly of claim 3, wherein the infrared light source comprises an array of infrared light sources.

5. The airbag and switch assembly of claim 2, wherein the at least one non-force sensor comprises a touch-based capacitive sensor.

6. The airbag and switch assembly of claim 1, wherein the airbag deployment portion comprises a front surface and a rear surface.

7. The airbag and switch assembly of claim 6, wherein the switch assembly further comprises a horn sensor, wherein the hom sensor is coupled to the rear surface of the airbag deployment portion.

8. The airbag and switch assembly of claim 6, wherein the rear surface of the airbag deployment portion comprises an l-shaped tear seam.

9. The airbag and switch assembly of claim 6, wherein the rear surface of the airbag deployment portion comprises an H-shaped tear seam.

10. The airbag and switch assembly of claim 1, wherein the rear surface comprises an array of activation zones and an array of walls, wherein each individual wall of the array of walls is disposed between two adjacent activation zones of the array of activation zones.

11. The airbag and switch assembly of claim 10, wherein each individual activation zone corresponds to an individual button zone of the array of button zones.

12. The airbag and switch assembly of claim 1, wherein the flexible circuit is coupled to a printed circuit board (PCB).

13. The airbag and switch assembly of claim 12, further comprising a haptic actuator coupled to the PCB, the haptic actuator configured to deliver haptic energy to the switch portion.

14. The airbag and switch assembly of claim 13, wherein the haptic actuator is a coneless voice coil and magnet assembly.

15. The airbag and switch assembly of claim 12, wherein the switch assembly further comprises a horn sensor, wherein the hom sensor is coupled to the PCB.

16. The airbag and switch assembly of claim 15, wherein the airbag deployment portion comprises a front surface and a rear surface, wherein the horn sensor is coupled to the rear surface of the airbag deployment portion.

17. The airbag and switch assembly of claim 1, further comprising a processor and a memory, the memory storing instructions for execution by the processor, wherein the instructions cause the processor to control a vehicle function in response to an activation force.

18. The airbag and switch assembly of claim 17, wherein each individual button zone of the array of button zones corresponds to a different vehicle function capable of being controlled by the processor.

19. The airbag and switch assembly of claim 17, wherein the switch assembly further comprises a printed circuit board (PCB), wherein the processor and the memory are coupled to the PCB.

20. The airbag and switch assembly of claim 17, wherein the processor and the memory are disposed in the vehicle spaced apart from the airbag and switch assembly.

Images