Abstract:
A bezel-button assembly comprising at least one button connected to a bezel. The button is moveable between a first position and at least a second position. An elastic layer connects the bezel to the button and is adapted to provide at least a partial mechanical bias of the button toward the first position. A method for forming a bezel-button assembly is also disclosed.

Description:
FIELD OF THE INVENTION 
   The present invention relates generally to a bezel including those with an integrated button. 
   BACKGROUND OF THE INVENTION 
   Switches and buttons are a part of everyday machine operation. Vehicle dashboards and other devices commonly include a multitude of switches and buttons for performing a multitude of operations. As a result, manufacturing of buttons and switches and their placement into the dashboards or other surfaces is a factor in the overall machine cost. Conventional manufacturing of buttons or other switch devices commonly incorporates a moveable button portion disposed in an outer shell or bezel, which surrounds the button. The bezel may provide an aesthetically pleasing or other suitable support surface while having the structure to allow a user to actuate the button. While such a system does allow buttons to operate within the bezel, some drawbacks may exist. For example, conventional manufacturing of button bezels typically requires multiple manufacturing steps to create the buttons and the bezel and then to assemble the buttons into the bezel. The present invention is developed in light of these and other potential drawbacks. 
   BRIEF SUMMARY OF THE INVENTION 
   The present invention comprises a button and bezel assembly including at least one button connected to a bezel. The button is moveable between a first position and at least a second position. An elastic layer connects the bezel to the button and is adapted to provide at least a partial elastic bias of the button toward the first (e.g., a “rest”) position. 
   Other aspects of the invention will be apparent to those skilled in the art after reviewing the drawings and the detailed description below. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The present invention will now be described, by way of example, with reference to the accompanying drawings, in which: 
       FIG. 1  is a perspective view of a top face of a bezel assembly according to an aspect of the present invention. 
       FIG. 2  is a perspective view of a rear face of a bezel assembly according to an aspect of the present invention. 
       FIG. 3  is an exploded perspective view of a bezel assembly according to an aspect of the present invention. 
       FIG. 4  is rear view of a bezel assembly according to an aspect of the present invention. 
       FIGS. 5 ,  6  and  7  are side cross sectional views of bezel assemblies according to aspects of the present invention. 
       FIG. 8  is a generic representation of a mold set. 
       FIG. 9  is an exploded view generally illustrating the assembly of an embodiment of the present invention. 
   

   DETAILED DESCRIPTION OF THE INVENTION 
   Referring now to  FIGS. 1 and 2 , a button bezel assembly  10  is shown including a bezel portion  12 ; a plurality of buttons, for example  14   a ,  14   b ,  14   c ,  14   d ,  14   e  and  14   f , that are disposed in the bezel portion  12 ; and a layer  20  attached or connected adjacent to bezel portion  12 . 
   In an embodiment of the invention, one or more hinge members  16  may be integrally formed with the buttons  14  and bezel  12 . For instance, each of the buttons  14  may be connected to the bezel portion  12  by hinge members, such as those illustratively represented as elements  16   a  and  16   b  in the cut-away segments of  FIG. 1 . It is however noted that multiple hinge member combinations (as shown) are not required. Moreover, hinge members are not required in all embodiments and may be eliminated from inclusion with respect the entire assembly or one or more buttons  14 . Nonetheless, when present, the hinge members may serve the added purpose of retaining the buttons  14  in a desired position during the formation or attachment of layer  20  to the bezel  12  over or about the buttons  14 . For instance, the hinge members  16  may, in addition to providing a hinge about which the buttons can move with respect to the bezel  12 , they may, at least in part, be used to hold the buttons in a desired position during the formation of layer  20  over or about the button. 
   In an embodiment of the invention, such as that depicted in  FIG. 1 , some buttons (e.g.,  14   a  and  14   b ) may be “rocker type” switches, while other buttons (e.g.,  14   c ,  14   d ,  14   e , and  14   f ) may be “push button” type switches. Of course, the associated button or buttons may be of any number or type and the present invention is not intended to be limited by the illustrative examples set forth herein. 
   With respect to embodiments including rocker type buttons, such as  14   a , hinge members  16   a  may be positioned on opposite sides of the buttons, to provide a general axis to divide the button generally into upper portions  18  and lower portions  19 . Such portions  18 ,  19  may be (such as with button  14   a ), but are not required to be, of similar dimensions. It is noted the “hinge members” or “hinges” are not limited to the type and sizes depicted in the exemplary illustrations. Further the hinge members may include or be comprised of pieces of integrally formed (or later added) connecting material between the buttons  14  and bezel  12 , which permit the associated button to flex, rotate, or otherwise move in response to pressing upper portions  18  or lower portions  19  of the buttons. As a result, the buttons can be moveable between a first position and a second position. For example, the first position can be a “neutral” or an unpushed (or equilibrium) state while the associated second position may a position in which either the upper or lower portion is pushed into (or extends out of) the bezel  12 . Of course, one skilled in the art will understand that variations of this may be used, such as having the first position be a pushed or actuated state while the second position is an unpushed or unactuated state. 
   Likewise, in the example shown, buttons  14   c ,  14   d ,  14   e  and  14   f  may also be connected to the bezel  12  by hinge members, such as those identified as  16   b  with respect to button  14   c . Such hinge members can permit portions of the buttons (e.g.,  14   c – 14   f ) to move into the bezel and/or rotate or flex about the associated hinge members. Buttons  14   c – 14   f  may also generally moveable between a first position and at least a second position. For example, without limitation, the first position can be an unpushed state while the second position take the form of a position in which the button is pushed into or meets a portion of the bezel. Of course, one skilled in the art will understand that variations of this may be used, such as having the first position a pushed state while the second position is an unpushed state. 
   In an embodiment of the invention, the material used to manufacture the bezel  12  and/or the buttons  14  may be comprised of rigid plastic such as a polypropylene, a teroplymer (e.g., acrylonitrile-butadiene-styrene, or ABS), or a nylon. Additionally, the bezel  12  and buttons  14  may be molded (i.e., injection, compression, etc.) together with a color material or dye disposed within the resin or molding material (as will be discussed in greater detail hereinafter). All or portions of the bezel  12  and/or buttons  14  may also be transparent or translucent to allow backlight to selectively pass therethrough. It should be understood however, that bezel  12  and buttons  14  are not limited to specific materials and may be formed of any suitable material, including, without limitation, metals, alloys, plastics, rubbers or other rigid material. It should be noted that hinge members  16  for all buttons  14  can be connected with or to any side or sides or surfaces of the associated buttons  14 . 
   Referring further to  FIG. 2 , a layer  20  is disposed on a rear side of the bezel  12 . It is noted that, the invention is not limited to such a configuration and other embodiments, discussed later herein, may in addition to or instead include a layer  20  disposed on the top side of the bezel  12 . In the instant embodiment, layer  12  is bonded, adhered, or otherwise connected to the back side of bezel  12  and buttons  14 . As depicted, layer  12  is connected to the back side of the bezel  12  such that the layer  20  substantially covers each button and may, as shown, cover a group of buttons. 
   In an embodiment of the invention, layer  20  is constructed of a flexible or elastomeric material that may elastically flex and/or deform and substantially return to form, i.e., an “elastic layer.” Layer  20  provides at least some elastic resistance to movement of buttons  14  and button bezel  10  to at least partially bias the buttons  14  towards their first position, which may be an equilibrium position. As a result, once a button  14  is moved to a second position, layer  20  at least partially biases the repositioned or actuated button back to its first position. Material used to produce layer  20  may include, without limitation, thermoplastic elastomers (TPEs), EBS, TPO or any other suitable elastomeric material. Portions of either or both layer  20  and bezel  12  may also be translucent or transparent, or may be etched away or otherwise removed, to allow the bezel, hinge member, button, and/or associated button graphics to be illuminated or back lit. Alternatively, if desired for a given application, one or more of the foregoing components may instead be shaded or colored. In an embodiment of the invention, layer  20  covers substantially an entirety of the space between the buttons  14  and bezel  12  to generally fill gaps between buttons  14  and bezel  12  and, among other things, help seal out dirt or other material from passing or penetrating from one side of bezel  12  to the other. 
   In operation, pressing upper portion  18  causes button  14   a  to rotate or pivot about hinge member or members, e.g.,  16   a , into a second position. An upper portion  18  may move into the bezel  12  while lower portion  19  may move out of the bezel  12 . Similarly, pressing buttons  14   c ,  14   d ,  14   e  or  14   f  can cause the respective buttons to move inward about hinge members  16   c ,  16   d ,  16   e  or  16   f , respectively, from a first position to a second position. The portion of the button  14  that moves into the bezel  12  can cause an electrical and/or mechanical element or switch to make contact or otherwise interact with additional components to signal or perform an associated operation. Once the button  14  is no longer pushed, the elastic bias of layer  20  has a tendency, at least in part, to move or generally return the button substantially back to its first position. However, as will readily be understood by those of skill in the art, other components, such as a spring (e.g., element  26  in  FIG. 5 ) or flexible structural component, may also be incorporated into the assembly to provide an additional means for returning a button to a desired position. 
   Referring now to  FIGS. 3 and 4 , other aspects of the invention are shown and described with respect to additional embodiments. In the assembly view of  FIG. 3 , a layer  20  is disposed on the top side of bezel  12 . The layer  20  is bonded, attached or otherwise connected to portions of the outer surface of bezel  12  as well as the top side of one or more buttons  14 . It should be understood that the layer  20  in connection with each of the various embodiments may cover varying amounts of the bezel  12  and the buttons  14 , and does not need to completely encapsulate the bezel  12  or the individual or collective buttons  14 . Instead, just enough connection between the bezel  12  and the buttons  14  is needed to allow the buttons  14  to be at least partially elastically biased by the layer and to cover or protect the space between the buttons  14  and the associated bezel  12  to the extent desired. However, it is recognized that for some applications complete encapsulation of an exposed surface of a bezel and associated buttons is desirable. 
     FIG. 4  depicts an example of a back side or bottom view of a simple single-button embodiment of the invention. In this embodiment, layer  20  is disposed on the top and sides of the bezel  12 . As shown, the button  14  may be integrally connected to one or more hinge members  16 . Depending upon the molding technique employed, layer  20  can completely or substantially surround the top surface and/or the sides of the button—i.e., around or about an associated hinge member  16  or, when no hinge member is present between the button and bezel, may help to function as a “living hinge” to support and permit movement of the button. With such configurations, the material of the layer  20  can work in conjunction with the hinge member  16  to help eliminate at least a portion of the mechanical stresses associated with the flexing, bending, or overpressing (or over extension) of the hinge member  16 . 
   The button  14  can additionally include a formation  22 , which may be integrally formed with the button  14  or may be a separate component in operable contact (electrical, magnetic, mechanical, etc.) with the button. When present, the formation can be used to support the button (e.g., to prevent over extension) and/or to interact with other components. For example, the formation can make contact with and translate a force or send a signal. Moreover, the bezel  12  may additionally include one or more bezel formations  24  that can be used to support the bezel and/or to connect or attach the bezel to other components, for example, a portion of a panel. 
     FIGS. 5 ,  6  and  7  illustrate cross sectional views of several embodiments of assemblies  10 , along with some optional features.  FIG. 5  depicts an embodiment in which the layer  20  generally surrounds a button  14  from the back or bottom side of the bezel  12 . The illustrated button  14  includes an attached or integral formation  22  that is intended to contact another component  28  when the button  14  is depressed a given distance. If desired, the assembly may include a spring  26  or other formation to help return the button to an initial or other desired position. In the illustration, the formation may be used to contact or otherwise mechanically, electrically, or magnetically interact with the component  28  to send a force or signal (indicated by a dashed line) to another component  30 , for example, a controller in a vehicle. 
     FIGS. 6 and 7  schematically represent embodiments in which portions of the buttons are “backlit” or otherwise illuminated. In the figures, the source of backlighting or illumination is schematically represented by a source  32 . The source may be comprised of a bulb, fiber optics, or any other known components or means for conveying sufficient light or energy to desired portions of the associated layer, button and/or bezel. 
   In  FIG. 6  the layer  20  is disposed on a portion of the back side or bottom portion of bezel  12 . Conversely,  FIG. 7  illustrates layer  20  disposed on a substantial portion of the top side of the bezel  12 . In embodiments in which the layer is not transparent or translucent, the layer  20  may be kept from forming upon (e.g., by mold design) or may be removed from all or portions of the face of a button such that the light or energy provided by the source  32 , when presented, can be externally perceptible. For instance, in an embodiment such as shown in  FIG. 6 , a portion of the layer  20 , e.g., as indicated at  34 , may be removed (e.g., by a laser) and, to the extent permitted by the material composition of the button, the energy or light provided by the source  32  will be perceptible. 
   Likewise, with respect to the embodiment shown in  FIG. 7 , the configuration may be designed such that the layer does not impede the desired external perception of the transfer of energy or light from the source  32 . It should be noted that, as presented in the exemplary embodiment shown in  FIG. 4 , the layer may be configured such that desired words or symbols (there the word “ON”) are presented to a user in connection with a button. Of course, as a matter of design, the words or symbols may be presented through portions of the bezel in addition to or instead of portions of associated buttons. Additionally,  FIG. 7  further shows details of a living hinge  21 . In  FIG. 7  the layer  20  is formed into at least one loop which peripherally envelops the button and spans the space between the button and the bezel; the loop provides an added degree of freedom so as not to restrict the movement of the button. 
   Referring to  FIGS. 8 and 9 , a method for creating button bezel  10  is generally described.  FIG. 8  is a generic representation of a mold set—such as those used for injection or compression molding—that may be used to form just a portion of a bezel or a bezel and one or more buttons  14 . The mold  22  may include cavities that are used to form the bezel  12  and buttons  14 , and in some instances, the associated hinge members  16 . In embodiments, such as that shown in  FIG. 9 , the bezel  12  and button  14  are integrally formed with and connected by one or more associated hinge members  16 , which, if desired, can all be formed in one formation step or shot. For example, a hot material (such as a plastic) can be injected or compressed into the mold  22  to form features of the bezel  12 , button  14  and the associated hinge member  16  (or other features intended to at least temporarily hold the button  14  in a desired position during subsequent formation of the layer  20 ). 
   In connection with the formation of the bezel  12 , a second mold (not shown) or other molding process can be used to form the associated layer  20 . In one particular embodiment, the second mold includes one or more cavities configured to form the contours, curves and configuration required to form layer  20  about all or a portion of the bezel  12 . As a result, a “two-shot” type of process may be used to form the assembly  10 . Depending upon the desired configuration, layer  20  may be formed on a top portion of the bezel, on a rear portion of the bezel, or both. Moreover, the heat associated with the formation of layer  20  may be used to effectuate bonding with corresponding portions of the associated bezel  12 . 
   In other embodiments, such as the one generally illustrated in  FIG. 9 , the layer  20  can be initially formed apart from the bezel  12  and later connected to it. If desired, the layer  20  can be reheated, or while the layer  20  is still at a sufficient temperature, it can be attached or bonded to the appropriate side of the bezel  12 . In instances in which there is added heat or residual heat associated with layer  20 , the heat can cause, facilitate or assist with the attachment or bonding between the layer  20  and the associated bezel  12 . It should be noted, however, that other methods of connecting layer  20  to bezel  12  may be used such as glue, adhesive, mating or connecting components or formations, or any other known means of connection. 
   While the present invention has been particularly shown and described with reference to the foregoing preferred and alternative embodiments, it should be understood by those skilled in the art that various alternatives to the embodiments of the invention described herein may be employed in practicing the invention without departing from the spirit and scope of the invention as defined in the following claims. It is intended that the following claims define the scope of the invention and that the method and apparatus within the scope of these claims and their equivalents be covered thereby. This description of the invention should be understood to include all novel and non-obvious combinations of elements described herein, and claims may be presented in this or a later application to any novel and non-obvious combination of these elements. The foregoing embodiments are illustrative, and no single feature or element is essential to all possible combinations that may be claimed in this or a later application. Where the claims recite “a” or “a first” element of the equivalent thereof, such claims should be understood to include incorporation of one or more such elements, neither requiring nor excluding two or more such elements.