Interior trim components with integrated electrical wiring

An interior trim component configured for use in a vehicle including a housing formed of a dielectric material and an electrical conductor encased within the housing being surrounded by and in intimate contact with the dielectric material forming the housing. The electrical conductor defines two exposed contact points. An exterior surface of the housing has a desired trim color and desired trim texture. The trim component may be manufactured using a 3D printing process or an insert molding process.

TECHNICAL FIELD OF THE INVENTION

The invention relates to interior trim components for vehicles, particularly trim components with integrated electrical wiring.

BACKGROUND OF THE INVENTION

Electrical wiring harnesses within the interior compartment (cockpit) of a vehicle are often covered by trim components, often referred to as trimpieces, having a desired color, shape, and texture on the exterior surface to provide an aesthetically pleasing appearance within the interior compartment. For example, wiring harness connecting lights, switches, and motors located above the vehicle headliner to the vehicle's electrical system are typically routed through the roof pillars. Trimpieces are attached to the roof pillars to hide the wiring harness from view of vehicle occupants. Another example is a trimpiece used to hide the wiring harness connection electrical devices in the rear view mirror to the vehicle's electrical system.

The wiring harnesses is first connected to the mating connectors in the vehicle and then the trimpiece is attached to the vehicle, thereby covering the wiring harness. This requires at least two separate labor steps by an assembly operator.

Vibration of the vehicle could cause the wiring harness to rattle against the trimpiece causing customer dissatisfaction and a reduction in wiring harness reliability, either of which could result in warranty repair claims for the vehicle manufacturer and suppliers. Additional countermeasures such as wire harness retaining clips and/or sound insulation on the inside surface of the trimpiece in order to avoid rattling may be required. Wiring and trim components that can avoid these assembly and rattle issues are desired.

BRIEF SUMMARY OF THE INVENTION

In accordance with an embodiment of the invention, an interior trim component configured for use in a vehicle is provided. The interior trim component includes a housing formed of a dielectric material and an electrical conductor encased within the housing being surrounded by and in intimate contact with the dielectric material forming the housing. The electrical conductor defines two exposed contact points.

The electrical conductor may be formed of a metallic material. The interior trim component may be formed by insert molding the electrical conductor within the interior trim component. Alternatively, the interior trim component may be formed by a 3D printing process depositing the dielectric material forming the housing and depositing a conductive material forming the electrical conductor.

The interior trim component may include a number of metallic electrical conductors. In this case, each conductor is encased within the housing and is surrounded by and in intimate contact with the dielectric material forming the housing and each electrical conductor defines two exposed contact points.

An exterior surface of the housing may have a desired trim color and desired trim texture.

The interior trim component may be configured to interconnect a rear view mirror to a vehicle electrical system.

DETAILED DESCRIPTION OF THE INVENTION

FIG. 1illustrates a non-limiting example of a rear view mirror assembly, hereinafter referred to as the mirror10. Mirrors in modern vehicles may include a wide variety of electrical and electronic components including, but not limited to, lights, switches, electrochromatic glass and light sensors for auto-dimming, and rear view camera displays. Therefore, in order to supply electrical power and signals from the vehicle's electrical wiring system to the mirror10, a mirror electrical connector12is connected to a vehicle electrical connector14by an interior trim component with integrated electrical wiring, hereinafter referred to as a trimpiece16.

Any number of attachment features known to those skilled in the art, such as snap locks or threaded fasteners, may be employed to attach the trimpiece16to the mirror connector12and vehicle connector14. The type of attachment feature selected may be dependent on the size constraints of the connectors and trimpiece16as well as ergonomic requirements of the assembly process of attaching the trimpiece16to the connectors.

As shown in the non-limiting example ofFIG. 2, the trimpiece16includes an enclosure or housing18that is formed of a dielectric, or electrically insulating, material such as acrylonitrile butadiene styrene (ABS) or polyamide (PA), commonly referred to as NYLON. The housing18encloses a number of electrical conductors20formed of an electrically conductive material, such as copper or aluminum based materials. The material forming the housing18surrounds and intimately contacts the conductive material forming the conductors20. The housing18provides electrical insulation for the electrical conductors20. Each conductor has two exposed contact points22, one on each end of the conductor, that are configured to interface with the mirror and vehicle connectors12,14. The housing18also provides proper dimensional spacing and location for the electrical conductors20and contact points22for proper mating with the vehicle and mirror connectors12,14.

As shown inFIG. 3, each of the contact points22are curved to provide a spring force for the contact points22against the mating contact points22of the vehicle and mirror connectors12,14. Alternatively, the contact points may comprise male pin or blade terminals configured to interface with mating female terminals in the vehicle and mirror connectors12,14or any other type of suitable electrical contact known to those skilled in the art.

The trimpiece16may be integrally formed using a 3D printing process capable of deposition of both dielectric and conductive materials, such as the process described by Shinas, et al. in U.S Patent Publication No. 2015/0201499 entitled DEVICE, SYSTEM, AND METHOD OF THREE-DIMENSIONAL PRINTING. The electrical conductors20and contact points22can be printed and integrated into the trimpiece16during the 3D printing process. The conductors20can also be layered and formed in any shape required for packaging.

Alternatively, the conductors20may be formed by stamping from a sheet of conductive material and then placed in a mold and insert molded within the housing18using an injection molding process.

The housing18may be formed so that an exterior surface24of the trimpiece16has a desired trim color and trim texture to match or compliment other interior trim components.

While the illustrated example of the trimpiece16is used to connect a mirror10to the vehicle electrical system, other embodiments of the trim piece may be used in other interior application, for example a roof pillar trimpiece that is used to connect the wiring in the vehicle headliner to the vehicle's' electrical system. Other embodiments may include structural elements formed of a dielectric material similarly encasing electrical conductors.

The trimpiece16described herein provides the benefits of reducing assembly time since making electrical connections and installing a trimpiece can be accomplished in a single operation rather than two separate operations of connecting a separate wiring harness and installing a separate trimpiece as was required previously. The trimpiece16also provides the benefit of eliminating rattles that could previously occur if a separate wiring harness contacted an interior surface of a separate trimpiece due to vibration. Producing the trimpiece16using 3D printing methods would further provide the benefits of a reduction in part numbers, tooling and labor costs.

While this invention has been described in terms of the preferred embodiments thereof, it is not intended to be so limited, but rather only to the extent set forth in the claims that follow. Moreover, the use of the terms first, second, etc. does not denote any order of importance, but rather the terms first, second, etc. are used to distinguish one element from another. Furthermore, the use of the terms a, an, etc. do not denote a limitation of quantity, but rather denote the presence of at least one of the referenced items.