Abstract:
A control system interface integrates an electronic switching or sensing mechanism with an existing or custom-fabricated, functional or decorative equipment panel. The electronic switching or sensing mechanism is located on the rear surface of the equipment panel and a corresponding touch surface is defined on the front surface of the equipment panel. The electronic switching or sensing mechanism is responsive to a stimulus in the proximity of the touch surface, and it provides a control signal to a control system when it senses such a stimulus.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
   This application claims priority from U.S. Provisional Patent Application Ser. No. 60/289,225 filed on May 7, 2001. 

   BACKGROUND OF THE INVENTION 
   1. Technical Field 
   The present invention relates generally to control system input apparatus and methods for making same. More particularly, the present invention relates to integration of electronic touch switches or sensors with shaped panels, such as decorative fascia and the like. 
   2. The Prior Art 
   Conventional electrical control panels typically comprise one or more mechanical or membrane switches installed on flat, or planar, panels having substantially uniform thickness and/or cross section. One known type of control panel includes one or more mechanical switches mounted on a flat panel having one or more apertures for accommodating the one or more mechanical switches. Such control panels are commonly used in connection with a wide variety of equipment, including industrial machines, automobile dashboards, and all sorts of consumer products. Another known type of control panel includes one or more membrane switches mounted on a substantially flat substrate and covered with a thin, flexible plastic overlay. The overlay helps to protect the underlying switches and circuitry from spills and moisture. The overlay also may incorporate a decorative design, such as a mimic of the switch layout mimic, thereon. Such control panels commonly are used in connection with exercise equipment (such as rowing machines and treadmills), gas pumps, and all sorts of other apparatus. 
   Certain disadvantages are inherent in the foregoing types of control panels. For example, the apertures inherent to mechanical switch panels provide a path for fluids and contaminants to enter the rear portion of the control panel, increasing the potential for short circuits and damage to components within the panel. Further, the mechanical switches themselves typically are assemblies of several individual parts which are subject to moisture or fluid intrusion. As such, mechanical switch panels are less than ideal for use in harsh environments, unless peripheral protective enclosures are provided. Such enclosures are costly, unsightly, and make the switch panel inconvenient to use. 
   Switch panels using membrane switches offer some protection to the elements by way of the flexible overlay. However, such overlays typically do not provide a complete barrier to moisture and fluids. Also, they are prone to damage resulting from ordinary use and cleaning. Further, they can become embrittled with age, particularly if used in harsh environments. The overlays can develop cracks, leading to failure of the moisture barrier. 
   Mechanical switches generally are substantially rigid devices best suited for mounting on a flat surface or substrate. Although the contact mechanism in a membrane switch is inherently somewhat flexible, the overall switch package is substantially rigid and best suited for mounting on a flat surface or substrate. Neither mechanical nor membrane switches are particularly well-suited for use with any panel shape other than flat. Though attempts have been made to use such conventional switches in connection with shaped panels, such as curved panels, such attempts typically have not yielded elegant solutions. It would be desirable to provide a switch panel having a free-form design whose contours are not limited to planar surfaces. 
   SUMMARY OF THE INVENTION 
   The present invention provides a novel control system input apparatus and a method for making same by integrating electronic touch switches and/or sensors (these terms are used interchangeably herein) with panels, such as decorative and/or functional fascia, having planar, curved, or complex surfaces. In a preferred embodiment, one or more touch switches are mated with the rear surface of a functional and/or decorative panel of an apparatus receiving control systems inputs from such touch switches. A corresponding touch surface is defined on the front surface of the panel opposite each such touch switch. In order to actuate one of the touch switches, a user simply introduces a stimulus, such as a finger or hand, in the proximity of the corresponding touch surface. 
   A control system input apparatus, or control panel, according to the present invention can take nearly any form. For example, it can have any number of convex or concave surfaces, or it can be a substantially planar panel having raised portions and/or depressions, i.e., a non-uniform cross-section or thickness, for enabling a user to more easily locate a particular touch switch. The present invention is well-suited for providing control panels for use with controlled apparatus exercise equipment and for integrating control panels into the decorative fascia of products such as vending machines and beverage dispensers of the type commonly found in fast food outlets, movie theaters, and the like. 
   A control panel according to the present invention preferably incorporates touch switches or sensors embodying technology covered by U.S. Pat. No. 5,594,222, U.S. Pat. No. 6,310,611 and/or U.S. Pat. No. 6,320,682, the disclosures of which are hereby incorporated by reference. Such touch switches are available from TouchSensor Technologies of Wheaton, Ill. A touch switch according to the foregoing references can be fabricated on a wide variety of substrates. For example, such a touch switch can be fabricated on a flexible sheet, as well as on a rigid substrate. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
       FIG. 1  is a plan view of a user interface for a piece of exercise equipment embodying the present invention; 
       FIG. 2  is a cross-sectional elevation view of an equipment panel according to a preferred embodiment of the present invention; 
       FIG. 3  is a cross-sectional elevation view of an equipment panel according to another preferred embodiment of the present invention; 
       FIG. 4  is a cross-sectional elevation view of an electronic switch panel integrated with an equipment panel according to a preferred embodiment of the present invention; 
       FIG. 5  is a cross-sectional elevation view of an electronic switch panel integrated with an equipment panel according to another preferred embodiment of the present invention; and 
       FIG. 6  is a cross-sectional elevation view of electronic switch panel integrated with an equipment panel according to a further preferred embodiment of the present invention. 
   

   DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     FIG. 1  illustrates a user interface  10  of a piece of exercise equipment, namely, a treadmill (not shown), embodying the present invention. User interface  10  includes a display  12  and a control panel  14 . Control panel  14  is a substrate including a plurality of touch surfaces, such as display control touch surfaces  16  which control various functions of display  12 , touch surfaces  18  for numerical input, touch surface  20  for resetting the treadmill&#39;s controls, touch surfaces  22  for adjusting the inclination of the treadmill&#39;s running surface, touch surface  24  for starting the treadmill, touch surfaces  26  for adjusting the treadmill&#39;s resistance, and touch surface  28  for indicating that data is to be entered to the treadmill&#39;s control system. 
   Control panel  14 , as shown in  FIG. 1 , is generally planar. In other embodiments, control panel  14  can take any desired curved or angular shape. For example, control panel  14  can include convex, concave, and or angular elements. 
   The front surface  30  of control panel  14  generally conforms to the contour of control panel  14 . That is, in the  FIG. 1  embodiment, control panel  14  is generally planar and front surface  30  thereof also is generally planar. Touch surfaces  18  are generally co-planar with front surface  30 . However, portions of control panel  14 , namely, touch surfaces  16 ,  20 ,  22 ,  26 , and  28  are recessed from front surface  30 . Another portion of control panel  14 , namely, touch surface  24 , is raised above front surface  30 . These features, which are more easily seen with reference to  FIGS. 2 and 3 , make it easier for a user to locate a particular touch surface through tactile means, in addition to or instead of visual means. Further, the switches or sensors (discussed further below) associated with raised touch surfaces, such as touch surface  24 , are less likely to be adversely affected by contaminants (especially liquid contaminants) because it is difficult, if not impossible, for contaminants to pool or settle about a raised surface. 
   The raised and recessed portions of front surface  30  can be achieved in various ways. For example,  FIG. 2  shows an embodiment wherein control panel  14  has multiple thicknesses. In this embodiment, control panel  14  generally has a first thickness  34  between front surface  30  and rear surface  36  (which is generally planar). Control panel  14  also has a second, reduced thickness  32  in the regions corresponding to, for example, touch surfaces  20 ,  22 ,  26 , and  28 . Control panel  14  further has a third, greater thickness  33  in the region corresponding to touch surface  24 .  FIG. 3  shows an alternate embodiment wherein control panel  14  has a substantially uniform thickness  38 , and wherein rear surface  36  generally conforms to front surface  30 . Other embodiments can use any combination of the foregoing techniques or any other suitable technique. 
     FIG. 4  illustrates a sensor panel  50  attached to the control panel  14  embodiment illustrated in FIG.  2 . Sensor panel  50  includes touch switches  40 ,  42 ,  44 ,  46 , and  48  formed onto substrate  52 . Each touch switch  40 ,  42 ,  44 ,  46 , and  48  is connected to a control system, control interface or control logic (not shown). Substrate  52  is generally planar and generally conforms to rear surface  36  of control panel  14 . In alternate embodiments, substrate  52  can be convex, concave, or take other shapes so as to be substantially conformable to rear surface  36 . Substrate  52  is positioned relative to control panel  14  so that touch switches  40 ,  42 ,  44 ,  46 , and  48  are aligned with corresponding touch surfaces  20 ,  22 ,  24 ,  26 , and  28 . In the  FIG. 4  embodiment, properly aligned substrate  52  is bonded to rear surface  36  of control panel  14  using an appropriate adhesive. In other embodiments, substrate  52  can be connected to rear surface  36  of control panel  14  by any other suitable means, such as mechanical fasteners. However, it is preferred that the attachment mechanism does not require perforation of control panel  14 . 
     FIG. 5  illustrates sensor panel  50  attached to the control panel  14  embodiment illustrated in FIG.  3 . In this embodiment, substrate  52  generally conforms to the portions of rear surface  36  adjacent touch surfaces  20 ,  22 ,  26 , and  28 , i.e., the “high points” of rear surface  36 . As in the  FIG. 4  embodiment, substrate  52  is positioned relative to control panel  14  so that touch switches  40 ,  42 ,  44 ,  46 , and  48  are aligned with corresponding touch surfaces  20 ,  22 ,  24 ,  26 , and  28 . Properly aligned substrate  52  preferably is bonded to rear surface  36  of control panel  14  using an appropriate adhesive. In other embodiments, substrate  52  can be connected to rear surface  36  of control panel  14  by any other suitable means, such as mechanical fasteners. However, it is preferred that the attachment mechanism does not require perforation of control panel  14 . 
     FIG. 6  shows a cross-sectional view of a curved control panel  100  embodying the present invention. Control panel  100  includes a number of touch surfaces  102 . A switch panel  106  including a number of touch switches  104  on a substrate  108  is bonded to control panel  100  using a suitable adhesive  110 . Control panel  100  generally has a first thickness  112 , and it has a second, reduced thickness  114  in the regions adjacent touch surfaces  102 . Alternatively, one or more regions of control panel  100  corresponding to one or more raised touch surfaces (not shown) could have increased thickness (not shown). 
   In operation, each touch switch, for example, touch switch  40 , sets up an electric field  60  in the proximity thereof. The introduction of a stimulus, for example, a user&#39;s finger (not shown), in the proximity of the electric field causes touch switch  40  to functionally change state and provide a corresponding input to an associated control system, control interface or control logic (not shown). This phenomenon is discussed more thoroughly in the foregoing U.S. patents incorporated herein by reference. 
   For example, if a user desired to start the treadmill whose control panel is shown in  FIG. 1 , the user would touch or bring his/her finger close to touch surface  24 . This action would disturb the electric field set up by corresponding touch switch  44 . In response, touch switch  44  would provide an output signal to the treadmill&#39;s control logic (not shown), which in turn would cause the treadmill to start. 
   The present invention allows integration of an electrical switching mechanism into an existing or custom-fabricated, functional and/or decorative panel, without the need to perforate the panel, as would be the case if conventional mechanical and/or membrane switches were to be used. For example, the decorative front panel of a vending machine or beverage dispenser (not shown) can be adapted for use as a control panel simply by defining touch surfaces at any desired location on the front of the decorative panel and providing associated touch switches at corresponding locations on the rear of the decorative panel, as described above. This allows for a novel and elegant solution to the problem of providing aesthetic and ergonomic control system input devices for all sorts of equipment. 
   The present invention thus has been described in terms of certain preferred embodiments. These embodiments are not to be construed as limiting the present invention, whose scope is defined by the claims appended hereto.