Patent Publication Number: US-7592559-B2

Title: Bezel and actuator

Description:
BACKGROUND OF THE INVENTION 
     The present invention relates to a bezel and actuator and to the method by which they are formed. 
     A known automotive vehicle instrument panel has actuators which are movable relative to a bezel to effect operation of electrical equipment associated with the vehicle. One or more of the actuators may be manually moved to effect operation of vehicle lights, heater, or air conditioner. Known bezel and actuator assemblies used in vehicles have interfaces with close tolerances. 
     In spite of these close tolerances, there have been complaints about the actuators having a loose feel and about noise due to rattle between the actuator and the is bezel. In addition, assembly of the actuators and the bezel is difficult. With some vehicles, there may be as many as fourteen actuators associated with a bezel. 
     Known assemblies of plastic, that is, polymeric materials, have had one part pivotal relative to another part. In order to facilitate construction of these parts, it has previously been suggested that the parts may be formed using in-mold assembly technology. This may be done in the manner disclosed in U.S. patent application Ser. No. 10/819,877 filed by Lewis and Blake on Apr. 7, 2004 and entitled A cabinet catch for use in a cabinet latch assembly and a method for making the catch. 
     SUMMARY OF THE INVENTION 
     The present invention relates to a new and improved bezel and actuator assembly and the method by which it is manufactured. The bezel and actuator assembly may include an actuator having a guide surface and a bezel having a guide surface which engages the guide surface on the actuator. One of the guide surfaces is formed by being molded against the other guide surface. The guide surfaces cooperate to guide movement of the actuator along a linear path relative to the bezel. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The foregoing and other features of the present invention will become more apparent upon a consideration of the following description taken in connection with the accompanying drawings wherein: 
         FIG. 1  is a schematic, partially broken away, pictorial illustration of a bezel and actuator assembly which is manufactured and operated in accordance with the present invention; 
         FIG. 2  is an exploded schematic pictorial illustration of components of the bezel and actuator assembly of  FIG. 1 ; 
         FIG. 3  is a perspective view, with parts omitted, of the bottom of  FIG. 1 ; 
         FIG. 4  is an enlarged schematic pictorial illustration of a portion of  FIG. 3 ; 
         FIG. 5  is an enlarged top plan view, taken generally along the line  5 - 5  of  FIG. 4 , illustrating a guide member which forms part of the actuator and a guide post which forms part of the bezel; 
         FIG. 6  is a schematic pictorial illustration depicting the manner in which the bezel is formed in a mold assembly; 
         FIG. 7  is a schematic pictorial illustration, generally similar to  FIG. 6 , depicting the manner in which the actuator is formed in the bezel with the mold assembly of  FIG. 6 ; 
         FIG. 8  is an embodiment of an actuator and bezel assembly having a plurality of actuators associated with a single bezel; and 
         FIG. 9  is a simplified schematic pictorial illustration of the bezel and actuator assembly of  FIG. 8  and further illustrating the relationship of the actuators to the bezel. 
     
    
    
     DESCRIPTION OF SPECIFIC PREFERRED EMBODIMENTS OF THE INVENTION 
     A bezel and actuator assembly  20  constructed in accordance with the present invention is illustrated schematically in  FIG. 1 . The bezel and actuator assembly  20  includes a bezel  22  and an actuator  24  (see  FIGS. 1 and 2 ). The actuator  24  is manually movable in a downward (as viewed in  FIGS. 1 and 2 ) direction along a linear path from the initial or unactuated position of  FIG. 1  to an actuated position. 
     Downward movement of the actuator  24  to the actuated position effects operation of switch assemblies  30  and  32  ( FIG. 2 ) from an unactuated condition to an actuated condition. The switch assemblies are disposed on a printed circuit board  34 . Upon being manually released, the actuator  24  moves upward along the linear path back to the unactuated position shown in  FIG. 1 . As this occurs, the switch assemblies  30  and  32  operate from the actuated condition to the unactuated condition. 
     Linear movement of the actuator  24  between its initial or unactuated position and its actuated position is guided by the bezel  22 . The bezel  22  has a guide surface  38  ( FIG. 2 ) which engages a guide surface  40  formed on a collar  44  ( FIG. 2 ) which extends around the actuator  24 . When the actuator  24  is in the unactuated position of  FIG. 1 , the guide surface  40  on the actuator  24  engages the guide surface  38  on the bezel  22  to hold the actuator  24  against sidewise movement and rattling. 
     The bezel guide surface  38  and actuator guide surface  40  guide initial movement of the actuator from its unactuated position toward its actuated position. Similarly, the bezel guide surface  38  and actuator guide surface  40  guide final upward movement (as viewed in  FIGS. 1 and 2 ) of the actuator  24  back to its unactuated position under the influence of springs in the switch assemblies  30  and  32 . 
     In order to facilitate formation and assembly of the actuator  24  and bezel  22 , they are made utilizing in-mold assembly technology. By using in-mold assembly technology, the actuator guide surface  40  is accurately molded, that is, shaped, by engagement with the bezel guide surface  38 . This results in consistent tolerances at an interfaces between the bezel guide surface  38  and actuator guide surface  40  being very tight (+/0.05 mm) to eliminate objectionable movement and noise due to rattle when the actuator  24  is in the unactuated position of  FIG. 1 . 
     In addition, the use of in-mold assembly technology for formation of the bezel  22  and actuator  24  facilitates assembling of the actuator and bezel. This is because the bezel  22  and actuator  24  are molded in an assembled condition. To enable the actuator  24  to be molded against the bezel  22 , the bezel is made of a plastic (polymeric) material which melts at a higher temperature than the plastic (polymeric) material of the actuator. Even though the actuator  24  is molded against the bezel  22 , bonds are not formed between the plastic material of the bezel and the plastic material of the actuator during molding. 
     If desired, the bezel  22  may be molded against the actuator  24 . If this is done, the bezel  22  would be made of a plastic which melts at a lower temperature than the plastic material of the actuator  24 . 
     The bezel guide surface  38  and actuator guide surface  40  cooperate to hold the actuator  24  against movement relative to the bezel  22  when the actuator is in the initial or unactuated position of  FIG. 1 . In addition, the bezel guide surface  38  and actuator guide surface  40  cooperate to guide initial relative movement between the actuator  24  and bezel  22  upon manual actuation of the actuator. However, the bezel guide surface  38  and actuator guide surface  40  have relatively short axial extents and therefore are effective to guide only a relatively small portion of movement between the actuator  24  and bezel  22  during manual actuation of the actuator. 
     Movement of the actuator  24  through an entire operating stroke relative to the bezel  22  is guided by cooperation between a plurality of bezel guide posts  50  ( FIGS. 3 and 4 ) and a plurality of actuator guide members  52 . The bezel guide posts  50  are integrally molded as one piece with the remainder of the bezel  22 . The actuator guide members  52  are integrally molded as one piece with the remainder of the actuator  24 . Although only two bezel guide posts  50  are illustrated in  FIGS. 3 and 4 , it should be understood that there are three guide posts which cooperate with three guide members  52 . 
     During movement of the actuator  24  relative to the bezel  22 , the actuator guide members  52  slide along linear guide channels  56  ( FIGS. 4 and 5 ) formed by the bezel guide posts  50 . The guide channels  56  have longitudinal central axes which extend perpendicular to a flat bottom surface  58  of the bezel  22 . The central axes of the guide channels extend parallel to the linear path of movement of the actuator  24 . 
     A portion of each of the guide members  52  remains in an associated guide channel  56  throughout movement of the actuator  24  between the initial or unactuated position and the actuated position. Thus, throughout linear movement of the actuator  24  from the initial or unactuated position to the actuated position, the guide members  52  move along the parallel guide channels  56  ( FIGS. 4 and 5 ). Similarly, throughout linear movement of the actuator  24  from its actuated position back to its initial or unactuated position, the guide members  52  move along the guide channels  56 . 
     End portions  60  of the guide members  52  engage the flat bottom surface  58  of the bezel  22  when the actuator  24  is in the unactuated position. The end portions  60  of the guide members  52  are pressed firmly against the bottom surface  58  of the bezel  22  by springs in the switch assemblies  30  and  32  to limit upward (as viewed in  FIG. 1 ) movement of the actuator  24  when the actuator is in the unactuated position. 
     The guide members  52  ( FIGS. 4 and 5 ) are molded against guide channels in the guide posts  50  during the in-mold assembly process in which the actuator  24  is molded in the bezel  22 . This results in the guide channel  56  having guide surfaces  70 ,  72  and  74  ( FIG. 5 ) which are parallel to guide surfaces  76 ,  78  and  80  on the guide members  52 . There is a small amount (+/0.05 mm) of uniform clearance between the guide surfaces  70 ,  72  and  74  on the guide posts  50  and the guide surfaces  76 ,  78  and  80 . This consistent clearance is formed by shrinkage of the plastic material of the bezel  22  during molding of the bezel. The tight and consistent clearance between the bezel guide surfaces  70 ,  72  and  74  and the actuator guide surfaces  76 ,  78  and  80  provides the actuator  24  with a stable feel as it is moved between its unactuated and actuated positions. 
     The plastic (polymeric) material of the guide members  52  is molded against the plastic (polymeric) material of the guide posts  50 . As the plastic material of the actuator  24  cools, the guide surfaces  76 ,  78  and  80  on the guide members  52  move away from the guide surfaces  70 ,  72  and  74  on the guide posts  50  to form clearance spaces in the manner illustrated schematically in  FIG. 5 . The uniform clearance spaces between the bezel guide surfaces  70 - 74  and the actuator guide surfaces  76 - 80  is approximately 0.05 mm. 
     It should be understood that  FIG. 5  is merely a schematic illustration of the clearance spaces which are formed by shrinkage of the polymeric material of the actuator  24  during molding. The actual clearance which is formed may be different than is illustrated schematically in  FIG. 5 . 
     As was previously mentioned, the bezel  22  may be molded against the actuator  24 . If this is done, the guide surfaces  70 - 74  ( FIG. 5 ) on the guide posts  50  would be molded against the guide surfaces  76 - 80  on the guide members  52 . As a result of shrinkage of the plastic (polymeric) material of the actuator  24 , small uniform clearance spaces of about 0.05 mm would be formed between the guide surfaces  76 - 80  on the guide members  52  and the guide surfaces  70 - 74  on the guide posts  50 . 
     A pair of actuator legs  86  and  88  ( FIGS. 3 and 4 ) extend from the lower (as viewed in  FIG. 1 ) side of the actuator  24 . The actuator legs  86  and  88  are engageable with the switch assemblies  30  and  32  ( FIG. 2 ) to actuate the switch assemblies upon movement of the actuator  24  from the unactuated position of  FIG. 1  to the actuated position. The actuator legs  86  and  88  extend parallel to the guide members  52  and to the linear path of movement of the actuator  24 . 
     The actuator leg  86  is engageable with the switch assembly  30  ( FIG. 2 ) to actuate the switch assembly. Similarly, the actuator leg  88  ( FIG. 4 ) is engageable with the switch assembly  32  ( FIG. 2 ). The switch assemblies  30  and  32  include a generally rectangular silicon membrane  92  ( FIG. 2 ) having a central opening. The membrane  92  is mounted on the circuit board  34 . 
     Known spring assemblies  96  and  98  are mounted on the membranes  92  and  94 . The spring assembly  96  is aligned with the actuator leg  86  ( FIG. 4 ) on the actuator  24 . Similarly, the spring assembly  98  is aligned with the actuator leg  88  on the actuator  24  ( FIGS. 2 and 4 ). The spring assemblies  96  and  98  have resiliently deflectable components which are deflected by force transmitted through the actuator legs  86  and  88 . Spring forces applied to the actuator legs  86  and  88  by the spring assemblies  96  and  98  are effective to move the actuator  24  from its actuated position back to its unactuated position. 
     The switches disposed beneath the membrane  92  are electrically connected with an apparatus to be operated in response to manual actuation of the actuator  24 . For example, the switches may be connected with lights, heating, air conditioning, or ventilation equipment in a vehicle. However, it should be understood that the bezel and actuator assembly  20  may be utilized in environments other than in association with a vehicle. For example, the bezel and actuator assembly  20  may be utilized in machine controls or in electronic devices. As a further example, each of the keys on a computer keyboard may be formed by an actuator  24  with an upper side of the keyboard being formed by the bezel  22 . 
     Although it is preferred to utilize known spring assemblies  96  and  98  in association with the actuator  24 , it is contemplated that other known types of spring assemblies and or switches may be utilized in association with the actuator if desired. For example, known maintained, alternate action, or momentary switches may be utilized in association with the actuator  24 . 
     A flexible finger  104  ( FIG. 4 ) cooperates with a cam stop  106  on the actuator leg  88  to limit the extent of downward (as viewed in  FIGS. 1 and 2 ) movement of the actuator  24  relative to the bezel  22  under the influence of gravity prior to connection of the bezel and actuator assembly  20  with the printed circuit board  34  and switch assemblies  30  and  32  ( FIGS. 1 and 2 ). When the actuator  24  has moved downward (as viewed in  FIG. 1 ) under the influence of gravity through a small predetermined distance relative to the bezel  62 , a ramp surface  108  ( FIG. 4 ) on the cam stop  106  engages the flexible finger  104 . The flexible finger  104  is then effective to stop downward movement of the actuator  24 . This effectively traps the actuator  24  to prevent disengagement of the actuator from the bezel  22  under the influence of gravity prior to connection of the bezel with the printed circuit board  34  and switch assemblies  30  and  32 . 
     Once the bezel  22  has been connected with the printed circuit board  34  in the manner illustrated in  FIG. 1 , downward movement of the actuator  24  to operate the switches  30  and  32  ( FIG. 2 ) is effective to press the ramp surface  108  on the cam stop  106  against the flexible finger  104  and to the deflect the flexible finger. This enables the actuator  24  to continue its downward (as viewed in  FIG. 1 ) movement to actuate the dome switches  96  and  98 . 
     During this continued downward movement, the flexible finger  104  is resiliently deflected toward the right (as viewed in  FIG. 4 ) by the cam stop  106 . This results in force being applied against actuator leg  88 . The force applied against the actuator leg  88  by the flexible finger  104  is effective to stabilize the actuator  24  against wobbling or sideward movement. 
     The ramp surface  108  on the actuator leg  88  extends at an angle of five (5) to seven (7) degrees relative to the linear path of movement of the actuator  24  and to the central axis of the actuator leg  88 . The flexible finger  104  has an end portion  110  with a side surface  112  which extends parallel to the ramp surface  108 . When, prior to assembly with the circuit board  34  and switches  30  and  32 , the actuator  24  has moved downward (as viewed in  FIG. 1 ) through a small distance relative to the bezel  22 , the ramp surface  108  on the actuator leg  88  is in flat abutting engagement with the side surface  112  on the flexible finger  104 . 
     When the actuator  24  is being injection molded in the opening formed by the bezel guide surface  38 , plastic material which is to form the ramp surface  108  of the cam stop  106  is in engagement with the flexible finger  104 . When the plastic material of the cam stop  106  cools, the plastic material shrinks. This shrinkage results in the formation of the initial space of approximately 0.05 mm between the ramp surface  108  and the side surface  112  on the flexible finger  104 . 
     The one piece, integrally molded actuator  24  includes a light pipe  114  ( FIG. 4 ). The light pipe  114  ( FIG. 4 ) has a cylindrical central conduit  116  through which light from a light source (not shown) on the printed circuit board  34  is conducted. The light conducted through the light pipe  114  is effective to illuminate an end panel or cap  120  ( FIG. 1 ) on the upper (as viewed in  FIG. 1 ) end of the actuator  24 . Although only a portion of the end panel  120  has been illustrated in  FIG. 1 , it should be understood that the end panel extends across the entire upper end of the actuator  24  and across the light pipe  114 . 
     The one piece, integrally molded bezel  22  is provided with a plurality of legs  124 ,  126 ,  128  and  130  ( FIG. 3 ) which extend downward (as viewed in  FIG. 1 ). The legs  124 - 130  are connected with the circuit board  34  by suitable fasteners  135  ( FIG. 2 ). In the specific embodiment illustrated in  FIG. 2 , the fasteners  135  are screws. It is contemplated that the bezel  22  may be connected with the circuit board  34  using fasteners other than screws. For example, a circuit board may be provided with upwardly extending projections which are received in openings in the legs  124 - 130 . Alternatively, fasteners at the lower ends (as viewed in  FIG. 1 ) of the legs  124 - 130  may be received in openings formed in the circuit board  34 . 
     The actuator  24  and bezel  22  are formed using in-mold assembly technology in the manner illustrated schematically in  FIGS. 6 and 7 . A mold assembly  140  has a cavity in which the bezel  22  is injection molded in the manner illustrated schematically in  FIG. 6 . 
     Once the bezel  22  has been molded, components of the mold assembly  140  are adjusted to provide a cavity corresponding to the configuration of the actuator  24 . The bezel  22  extends around the cavity corresponding to the configuration of the actuator  24 . This enables the actuator  24  to be injection molded to a desired configuration by components of the mold assembly and by engagement with the previously molded bezel  22 . Injection molding of the actuator  24  in the central opening in the bezel results in the bezel and actuator being assembled in the mold assembly  140  in the manner illustrated schematically in  FIG. 7 . The bezel  22  and actuator  24  are removed together, as a unit, from the mold assembly  140 . Therefore, there is no subsequent assembly of the bezel  22  and actuator  24  after they have been removed from the mold assembly  140 . 
     The actuator  24  may advantageously be formed of a plastic (polymeric) material having a melting temperature which is lower than the melting temperature of a plastic (polymeric) material forming the bezel  22 . For example, the bezel  22  may be formed of polycarbonate/acrylonitrile butadiene styrene while the actuator  22  is formed of an acetal. Of course, different plastic (polymeric) materials may be utilized to form the actuator  24  and bezel  22  if desired. 
     The mold assembly  140  may be of the multi-shot injection mold type. Although the bezel  22  has been described herein as being formed before the actuator  24 , it is contemplated that the actuator may be formed first and the bezel subsequently molded around the actuator. If this is done, surface areas on the bezel  22  would be shaped by engagement with surface areas on the actuator  24 . 
     Only a single actuator  24  is associated with the bezel  22  in the embodiment of the invention illustrated in  FIGS. 1-7 . In the embodiment of the invention illustrated in  FIGS. 8 and 9  a plurality of actuators are associated with a bezel. Each of the actuators in the embodiment of the invention illustrated in  FIGS. 8 and 9  has a construction which is the same as the construction of the actuator  24  of  FIGS. 1-7 . The actuators of the embodiment of the invention illustrated in  FIGS. 8 and 9  cooperate with a bezel in the same manner as previously described in conjunction with the embodiment of the invention illustrated in  FIGS. 1-7 . 
     In the embodiment of the invention illustrated in  FIGS. 8-9 , a bezel  150  is intended to be mounted on the dashboard of an automotive vehicle. Actuators  154  are individually manually actuatable to effect operation of vehicle heating, air conditioning and ventilation controls. In addition, the actuators  154  ( FIG. 8 ) control the operation of heated seats in the vehicle. The actuators  154  have end panels or caps  158  corresponding to the end panel  120  of  FIG. 1 . Indicia is provided on the end panels  158  ( FIG. 8 ) to indicate the various functions which are to be controlled by operation of the actuators  154 . 
     When the actuators  154  are manually pressed, that is, moved toward the bezel  150 , switches disposed in the dashboard behind the bezel  150  are actuated. The switches control the function which is indicated by the indicia on the end panel  158  of each of the actuators. The end panels  158  are provided with transparent sections or windows  162  which are aligned with light pipes in the actuators  154 . The actuator light pipes have the same construction as the light pipe  114  of the embodiment of the invention illustrated in  FIGS. 3 and 4 . 
     A separate light source is provided in association with the light pipe for each of the actuators  154 . When the actuator  154  is moved along a linear path relative to the bezel  150  to actuate an associated switch, the light source for the actuator is energized so that light is transmitted through the light pipe of the actuator to the transparent section  162  of the end panel  158  for the actuator. 
     The actuators  154  are illustrated in  FIG. 9  with the end panels  158  removed. The actuators  154  reciprocate along linear paths which extend perpendicular to a flat upper (as viewed in  FIG. 9 ) side surface  168  of the bezel  150 . Recesses  170  are provided in the bezel  150  to receive rotary knobs or other control elements. Thus, both rotary and linearly movable actuators are associated with the bezel  150 . The actuators  154  are movable linearly and the knobs associated with the recesses  170  are rotatable relative to the bezel. 
     The bezel  150  and actuators  154  of  FIGS. 8 and 9  are formed using in-mold assembly technology in the same manner as previously described in connection with the embodiment of the invention illustrated in  FIGS. 1-7 . The bezel  150  is molded in a mold cavity having a configuration corresponding to the desired configuration of the bezel. The actuators  154  are subsequently molded in a mold assembly with the actuators in the same spatial relationship as is illustrated in  FIGS. 8 and 9 . Components of the mold assembly are then moved to form actuator mold cavities aligned with the bezel  150 . 
     The actuator mold cavities are filled with plastic (polymeric) material having a melting temperature which is lower than the melting temperature of the plastic (polymeric) material forming bezel  150 . The plastic material of the actuator  154  is molded against surfaces on the bezel  150  in the same manner as previously described in conjunction with the embodiment of the invention illustrated in  FIGS. 1-7 . 
     From the above description of the invention, those skilled in the art will perceive improvements, changes and modifications. Such improvements, changes and modifications within the skill of the art are intended to be covered by the appended claims.