Patent Publication Number: US-2021180775-A1

Title: 3d icon for use with a switch and a mehtod of making the 3d icon

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
     This application claims the benefit of U.S. Provisional Patent Application Ser. No. 62/947,861 filed on Dec. 13, 2019, the contents of which are incorporated herein by reference thereto. 
    
    
     BACKGROUND 
     Exemplary embodiments of the present disclosure pertain to the art of control icons and more particularly, an icon for use with a non-moving switch and a method of making the icon. 
     Control icons are images an operator sees on pushbuttons that indicate what the function of that button is. Typically, these icons are very simplified two dimensional (2D) images, which are located on a moving switch (e.g., pushbutton, rocker or dial). Accordingly, it is desirable to provide a more aesthetically pleasing icon. 
     BRIEF DESCRIPTION 
     Disclosed is an assembly including a three dimensional icon defined within an interior of the assembly; the assembly including a non-moveable switch; a device for illuminating the three dimensional icon, wherein illumination of the three dimensional icon by the device causes the three dimensional icon to be visible on an exterior surface of the assembly. 
     In addition to one or more of the features described above, or as an alternative to any of the foregoing embodiments, the assembly further includes a polycarbonate substrate layer and the three dimensional icon is molded into the polycarbonate substrate layer. 
     In addition to one or more of the features described above, or as an alternative to any of the foregoing embodiments, the assembly further includes a layer of polyurethane applied to the polycarbonate layer. 
     In addition to one or more of the features described above, or as an alternative to any of the foregoing embodiments, the non-moveable switch is a capacitive sensor integrated with a printed circuit board. 
     In addition to one or more of the features described above, or as an alternative to any of the foregoing embodiments, the non-moveable switch is a printed touch sensor integrated into a flexible film located on a forward facing surface of the polycarbonate substrate layer that is disposed adjacent to the layer of polyurethane. 
     In addition to one or more of the features described above, or as an alternative to any of the foregoing embodiments, the flexible film is injection molded with the polycarbonate substrate layer. 
     In addition to one or more of the features described above, or as an alternative to any of the foregoing embodiments, the assembly is a portion of a vehicle interior. 
     In addition to one or more of the features described above, or as an alternative to any of the foregoing embodiments, the device is a light emitting diode (LED). 
     In addition to one or more of the features described above, or as an alternative to any of the foregoing embodiments, the assembly further includes a polycarbonate substrate layer and an icon sub-assembly inserted into an opening located in the polycarbonate substrate layer and a layer of polyurethane applied to the polycarbonate layer, wherein the icon sub-assembly includes the three dimensional icon and the device for illuminating the three dimensional icon. 
     In addition to one or more of the features described above, or as an alternative to any of the foregoing embodiments, the non-moveable switch is a sensor ring located about a periphery of the icon sub-assembly. 
     In addition to one or more of the features described above, or as an alternative to any of the foregoing embodiments, the icon sub-assembly has a frame that surrounds the device for illuminating. 
     In addition to one or more of the features described above, or as an alternative to any of the foregoing embodiments, the frame is formed from a polycarbonate material. 
     In addition to one or more of the features described above, or as an alternative to any of the foregoing embodiments, the frame is opaque. 
     In addition to one or more of the features described above, or as an alternative to any of the foregoing embodiments, the frame includes a flange portion that engages a back side of the polycarbonate substrate layer about a periphery of an opening in the polycarbonate substrate layer that the icon sub-assembly is inserted into. 
     In addition to one or more of the features described above, or as an alternative to any of the foregoing embodiments, the non-moveable switch is formed from a clear conductor that is located on a top of the icon sub-assembly. 
     In addition to one or more of the features described above, or as an alternative to any of the foregoing embodiments, a flange is located between end portions of the frame and the flange engages a forward facing surface of the polycarbonate substrate layer located adjacent to the layer of polyurethane. 
     In addition to one or more of the features described above, or as an alternative to any of the foregoing embodiments, the non-moveable switch is integrated with a printed circuit board and the device for illuminating is provided by side firing light emitting diodes (LEDS). 
     In addition to one or more of the features described above, or as an alternative to any of the foregoing embodiments, an area below features of the three dimensional icon is filled with a clear material. 
     In addition to one or more of the features described above, or as an alternative to any of the foregoing embodiments, the non-moveable switch is a capacitive touch pad located behind the three dimensional icon. 
     In addition to one or more of the features described above, or as an alternative to any of the foregoing embodiments, the three dimensional icon is a laser drawn three dimensional image within a volume of plastic located above the non-moveable switch. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The following descriptions should not be considered limiting in any way. With reference to the accompanying drawings, like elements are numbered alike: 
         FIG. 1  is cross-sectional view of an illuminated icon and corresponding switch formed in accordance with an embodiment of the present disclosure; 
         FIG. 2  is cross-sectional view of an illuminated icon and corresponding switch formed in accordance with an embodiment of the present disclosure; 
         FIG. 3  is cross-sectional view of an illuminated icon and corresponding switch formed in accordance with an embodiment of the present disclosure; 
         FIG. 4  is cross-sectional view of an illuminated icon and corresponding switch formed in accordance with yet another embodiment of the present disclosure; 
         FIG. 5  is cross-sectional view of an illuminated icon and corresponding switch formed in accordance with yet another embodiment of the present disclosure; 
         FIG. 6  is cross-sectional view of an illuminated icon and corresponding switch formed in accordance with yet another embodiment of the present disclosure; 
         FIG. 7  is cross-sectional view of an illuminated icon and corresponding switch formed in accordance with yet another embodiment of the present disclosure; 
         FIG. 8  is cross-sectional view of an illuminated icon and corresponding switch formed in accordance with yet another embodiment of the present disclosure; and 
         FIG. 9  is perspective view of an illuminated icon and corresponding switch formed in accordance with the present disclosure. 
     
    
    
     DETAILED DESCRIPTION 
     A detailed description of one or more embodiments of the disclosed apparatus and method are presented herein by way of exemplification and not limitation with reference to the Figures. 
     Illustrated in the attached FIGS. are various embodiments of an illuminated icon and corresponding switch for the illuminated icon. For example, the icon may be one illustrative of a fan and the switch is a switch that turns the fan on and off 
     In the disclosed embodiments, the touch point or switch does not move. As such and in one non-limiting embodiment, a capacitive sensor may be used for the switch. Thereafter, the icon or symbol for the control surface can be arranged to provide a three dimensional shape since the icon does not move. 
     In one embodiment of the present disclosure a three dimensional shape is molded in a back side of a substrate and the three dimensional appearance of the image can be enhanced with forward facing or side emitting light emitting diodes LEDs. Therefore and when an operator of the switch looks at the control surface the icon is three dimensional and thus has a more aesthetically pleasing appearance. In another non-limiting embodiment, the molded three dimensional shape can be backfilled with another clear material that has a different refractive index. This filled in portion can facilitate the use of a capacitive touch pad behind the icon since there is no longer an air gap above the capacitive touch pad. 
     In another non-limiting embodiment of the present disclosure a laser is used to draw a three dimensional image of the icon within the volume of plastic. This method may be referred to as sub-surface laser engraving. By focusing a laser on a very specific point in the three dimensional volume of plastic a void is created at that point in space and an image is created. This image, when illuminated appears as a three dimensional object. 
     Referring now to  FIG. 1 , as assembly  10  of a three dimensional icon  12 , a corresponding non-moveable switch or sensor  14  and a means or device for illuminating  16  the three dimensional icon  12  is illustrated. As used herein, a non-moveable switch or sensor  14  may be referred to as a capacitive sensor or other equivalent device that when is placed in close proximity to an operator&#39;s finger a switch or circuit is closed without any components moving. In one non-limiting embodiment, the assembly  10  may be a portion of a vehicle interior such as instrument panel or console or center console or armrest of the vehicle. In the  FIG. 1  embodiment, a printed circuit board (PCB)  18  is provided with the non-moveable switch or sensor  14  and the means or device for illuminating  16  the three dimensional icon  12 . In one embodiment, the means or device for illuminating is a light emitting diode (LED). 
     In the  FIG. 1  embodiment, the icon  12  is molded into a polycarbonate substrate layer  20  by for example, any suitable molding process such as injection molding, etc. Then, a clear layer of polyurethane  22  is applied to the polycarbonate layer  20 . In order to prevent the printed circuit board  18  from being viewed through the layer of polyurethane  22  and the polycarbonate layer  20 , an opaque masking layer  24  is located between the printed circuit board  18  and the polycarbonate layer  20 . The opaque masking layer  24  is provided with an opening  26  so that light emitting from the means for illuminating  16  is directed to the icon  12 . As illustrated, a back side of the icon  12  can be shaped with features  28  in order to create a shadowing effect within the icon  12  when it is illuminated by the means for illuminating  16 . As such, a three dimensional icon will be viewable from an exterior surface or control surface  36  of the polycarbonate layer  20  when it is illuminated by the means for illuminating  16 . The features  28  of the three dimensional icon are defined or located within an interior of the assembly  10 . In this embodiment, the non-moveable switch or sensor  14  (e.g., capacitive sensor or otherwise) is integrated with or integral with the printed circuit board  18 . 
     Referring now to  FIG. 2  another embodiment of the present disclosure is illustrated. In this embodiment, the non-moveable switch or sensor  14  is a printed touch sensor integrated into a flexible film  30  located on a forward facing surface  32  of the polycarbonate substrate layer  20  that is disposed adjacent to the polyurethane layer  22 . In one embodiment, the flexible film  30  is a formed film with the necessary conductive traces. In this embodiment, the flexible film  30  has an opening  34  in order to allow for the three dimensional icon  12  to be viewed from the exterior surface  36  of the polyurethane layer  22 . In this embodiment, the means for illuminating  16  is secured to a substrate layer  38 . In one embodiment, the flexible film  30  is injection molded with the polycarbonate substrate layer  20 . 
     Referring now to  FIG. 3  another alternative embodiment of the present disclosure is illustrated. Here the assembly  10  comprises an icon sub-assembly  40  that is inserted into an opening or recess  42  located in the polycarbonate substrate layer  20  and then the clear layer of polyurethane  22  is applied to the polycarbonate layer  20 . In this embodiment, the icon sub-assembly  40  includes the three dimensional icon  12  including the features  28  and the means for illuminating  16  (e.g., LED). In this embodiment, the non-moveable switch or sensor  14  is a sensor ring located about the periphery of the icon sub-assembly  40 . In this embodiment and in order to prevent the possibility of a “halo effect” from the means for illuminating  16  the icon sub-assembly  40  has a frame  44  that surrounds the means for illuminating  16 . The frame  44  may also be formed from a polycarbonate material. In order prevent this “halo effect” the frame  44  is formed out of an opaque material. In this embodiment, the frame  44  of the icon sub-assembly  40  also includes a flange portion  46  that engages a back side  48  of the polycarbonate substrate layer  20  about the periphery of opening  42  as the icon sub-assembly  40  is inserted into opening  42  in the direction of arrow  50 . In this embodiment, the polycarbonate substrate layer  20  may be formed in the same color as the desired location or usage (e.g., same color as the interior trim into which the assembly  10  is incorporated). Similarly, the frame  44  of the icon sub-assembly  40  may be formed in the same color as the desired location or usage (e.g., same color as the interior trim into which the assembly  10  is incorporated). 
     Referring now to  FIG. 4 , another embodiment of the present disclosure is illustrated. The  FIG. 4  embodiment is similar to the  FIG. 3  embodiment however; the non-moveable switch or sensor  14  is formed from a clear conductor  52  that is located on a top  54  of the icon sub-assembly  40  as opposed to a sensor ring located about the periphery of the icon sub-assembly  40 . The clear conductor  52  ensures that the three dimensional icon  12  is viewable from the surface  36 . 
     Referring now to  FIG. 5 , another embodiment of the present disclosure is illustrated. The  FIG. 5  embodiment is similar to the  FIG. 4  embodiment however, the icon sub-assembly  40  is configured to be inserted through the forward facing surface  32  of the polycarbonate substrate layer  20  in the direction of arrow  56 . In this embodiment, the flange  46  is located between opposite ends of the frame  44  and the flange  46  engages surface  32  once it is inserted into opening  42  in the direction of arrow  56 . Similar to the  FIG. 4  embodiment, the non-moveable switch or sensor  14  is formed from a clear conductor  52  that is located on a top  54  of the icon sub-assembly  40  as opposed to a sensor ring located about the periphery of the icon sub-assembly  40 . The clear conductor  52  ensures that the three dimensional icon  12  is viewable from the surface  36 . 
     Referring now to  FIG. 6 , yet another embodiment of the present disclosure is illustrated. As in the previous embodiments, the three dimensional icon  12  is molded into the polycarbonate substrate layer  20  by for example, any suitable molding process such as injection molding, etc. Then, a clear layer of polyurethane  22  is applied to the polycarbonate layer  20 . In this embodiment, the non-moveable switch or sensor  14  is integrated with the printed circuit board  18  and the means for illuminating  16  is provided by side firing light emitting diodes (LEDS). 
     Referring now to  FIG. 7 , another embodiment of the present disclosure is illustrated. This embodiment is similar to the  FIG. 6  embodiment however and in this embodiment, an area  58  below the features  28  of the three dimensional icon is filled with a clear material  60 . Non-limiting examples of the clear material  60  include epoxy, acrylic, plexiglass, Poly (methyl methacrylate) (PMMA), silicone, or other polycarbonates and equivalents thereof. This clear material will have a different refractive index than the polycarbonate layer  20 . This filled in portion can facilitate the use of a capacitive touch pad behind the icon since there is no longer an air gap above the capacitive touch pad. 
     In another non-limiting embodiment of the present disclosure and referring now to  FIG. 8 , a laser is used to draw a three dimensional image of the icon within a volume of plastic  62  located above the non-moveable switch or sensor (e.g., capacitive sensor)  14  is integrated with the printed circuit board  18  and the means for illuminating  16  is provided by side firing light emitting diodes (LEDS). The use of a laser to draw the three dimensional image may be referred to as sub-surface laser engraving wherein a laser is focused on a very specific point in the three dimensional volume of plastic  62  and a void is created at that point in space in order to define the three dimensional icon and/or an image is created. This image, when illuminated appears as a three dimensional object. 
       FIG. 9  is a partial perspective cross-sectional view of an assembly  10  contemplated for at least the embodiments illustrated in  FIGS. 6-8 . 
     The term “about” is intended to include the degree of error associated with measurement of the particular quantity based upon the equipment available at the time of filing the application. For example, “about” can include a range of ±8% or 5%, or 2% of a given value. 
     The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the present disclosure. As used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises” and/or “comprising,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, element components, and/or groups thereof. 
     While the present disclosure has been described with reference to an exemplary embodiment or embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the present disclosure. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the present disclosure without departing from the essential scope thereof. Therefore, it is intended that the present disclosure not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this present disclosure, but that the present disclosure will include all embodiments falling within the scope of the claims.