Abstract:
A portion of an automobile interior is provided with buttons, lenses or the like integrated into a protective cover of the automobile interior. By incorporating the buttons, lenses and the like into the protective cover of the automobile interior, additional parts typically necessary to perform the desired functions can be eliminated. The elimination of the additional parts results in a lower cost and reduced number of steps necessary for assembly. Additionally, the elimination of the additional parts results in a reduction in the number of apertures in the protective cover and the likelihood of component failure and/or manufacturing defects associated with the additional parts.

Description:
[0001]    This application claims priority to U.S. Provisional Application No. 60/883,701, filed Jan. 5, 2007, which is incorporated herein by reference in its entirety. 
     
    
     FIELD 
       [0002]    The present invention relates generally to a film, and a plastic substrate molded behind the film, with relief areas in the plastic substrate to allow integration of various features, into the film, such as lenses, bezels, buttons usable to actuate switches for various functions in the interior of an automobile, including lamp power, Homelink® and other electrical functions, and the like. 
       BACKGROUND 
       [0003]    Automobile interiors, including overhead consoles, typically comprise a variety of protective covers. These protective covers typically makeup a portion of, or the entirety of, the exposed surface that is visible to a user of the automobile. As such, the protective covers are vulnerable to dirt and debris present in the automobile interior. 
         [0004]    Typically, apertures are formed in these protective covers, with one or more buttons, lenses and the like fitted to and extending through the aperture such that they are accessible to a user. The buttons may be used to activate switches. The buttons may be formed by a variety of manufacturing processes, including stamping and/or injection molding. The apertures used for the buttons, lenses and the like may allow dirt and debris to collect beneath the protective cover of the automobile interior and/or between the protective cover and the buttons, lenses and the like. Furthermore, by incorporating buttons, lenses and the like that are separate from the protective cover, the existing designs require numerous parts and steps for assembly. 
       SUMMARY 
       [0005]    By limiting or eliminating the apertures that are conventionally formed in the protective cover, dirt and debris can be kept on the outside surface of the automobile interior, where the dirt and debris is more easily cleaned and/or removed. Additionally, by reducing the number of parts in an automobile interior as well as the steps necessary for assembling those parts, the production cost of the vehicle interior, and thus the vehicle as a whole, can be reduced. The reduced number of parts may also reduce the possibility of component failure and/or manufacturing defects associated with the additional parts. Additionally, this allows the functionality and customizable features of automobile interiors to be improved. 
         [0006]    The number of parts in an automobile interior, and the steps necessary to assemble those parts, can be reduced by providing an automobile interior with features, such as lenses, bezels and buttons, that are provided as functional regions of the protective cover of the automobile interior. This reduction in the parts of and in the steps necessary to assemble the parts into, an automobile interior results in reduced capital and its associated costs as well as costs involved in assembly. Additionally, by providing functional features, such as lenses, bezels and buttons, as portions of the protective cover of the automobile interior, a reduction of the number of apertures necessary in the protective cover can also be achieved. This reduced number of apertures in the protective cover results in a better sealed automotive interior, which is easier to clean. 
         [0007]    This invention relates to an automobile interior, or a portion of an automobile interior, that includes a protective outer layer. The protective outer layer includes a film layer with a plastic substrate provided behind the film layer. The film layer includes at least one functional region. In some embodiment, an aperture in the plastic substrate is substantially aligned with each functional region. 
         [0008]    The functional region is a region of the film layer that allows interaction or manipulation with a mechanical, electrical or other type of control device beneath the film layer that frames, surrounds or covers a design and/or functional aspect of the protective outer layer, and/or that transmits light or the like through the protective outer layer. For example, the functional region may allow interaction with a plunger of a push button switch located beneath the film layer and substantially aligned with the aperture in the plastic substrate and the functional region of the film layer. Likewise, the functional region may allow interaction with a capacitance switch located beneath the film layer and substantially aligned with the aperture in the plastic substrate and the functional region. The functional region may be a bezel or a lens that surrounds, frames or covers a feature of the protective cover, such as a toggle or other switch, a dome, map, reading or other interior light or the like. 
         [0009]    It should be appreciated that the functional region is a part of the film layer and is formed into the film layer or provided in the film layer during manufacture of the film layer. In some embodiments, additional parts or material may be inserted into a mold of the film layer to produce the functional region. However, after the film layer is molded, any additional parts or materials necessary for the production of the functional region become part of the film layer. 
         [0010]    This invention further relates to an automobile interior, or a portion of an automobile interior, that includes a protective outer layer. The protective outer layer includes a film layer with a plastic substrate molded behind the film layer. The film layer includes at least a first bezel or bezel appearance region of the film. 
         [0011]    This invention further relates to an automobile interior, or a portion of an automobile interior, that includes a protective outer layer. The protective outer layer includes a film layer with a plastic substrate molded behind the film layer. The film layer includes at least a first lens or lens appearance region of the film. 
         [0012]    These and other features and advantages of various exemplary embodiments of structures and methods according to this invention are described in, or are apparent from, the following detailed descriptions of various exemplary embodiments of various devices, structures and/or methods according to this invention. 
     
    
     
       DRAWINGS 
         [0013]    Various exemplary embodiments of the systems and methods according to this invention will be described in detail, with reference to the following figures, wherein: 
           [0014]      FIG. 1  is a representation of an overhead console assembly comprising one embodiment of an exemplary film layer according to this invention; 
           [0015]      FIG. 2  is a sectional view of a portion of an exemplary film layer according to this invention; 
           [0016]      FIG. 3  is a plan view of a portion of an exemplary film design; 
           [0017]      FIG. 4  is sectional representation of a portion of an exemplary film layer according to this invention; 
           [0018]      FIG. 5  is a plan view of a portion of an exemplary film layer according to this invention; 
           [0019]      FIG. 6  is a sectional view of a portion of a second exemplary film layer according to this invention; 
           [0020]      FIG. 7  contains sectional views of a portion of a third and fourth exemplary film layers according to this invention; 
           [0021]      FIG. 8  is a perspective view of a portion of an exemplary film layer according to this invention; 
           [0022]      FIG. 9  is a sectional view of a portion of an exemplary film layer according to this invention; 
           [0023]      FIG. 10  is an exploded view of a conventional overhead console; 
           [0024]      FIG. 11  is an exploded view of an exemplary overhead console comprising an exemplary film layer according to this invention; 
           [0025]      FIG. 12  is an exploded view of an exemplary overhead console comprising an exemplary film layer according to this invention; 
           [0026]      FIG. 13  is an exploded view of an exemplary overhead console comprising an exemplary film layer according to this invention; 
           [0027]      FIG. 14  is an exploded view of a second conventional overhead console; 
           [0028]      FIG. 15  contains perspective views of exemplary overhead console assemblies comprising an exemplary film layer according to this invention; 
           [0029]      FIG. 16  contains perspective views of exemplary overhead console assemblies comprising an exemplary film layer according to this invention; 
           [0030]      FIG. 17  is an exploded view of an exemplary lighting assembly comprising an exemplary film layer according to this invention; 
           [0031]      FIG. 18  is a perspective view of an exemplary lighting assembly comprising an exemplary film layer according to this invention; 
           [0032]      FIG. 19  is a perspective view of an exemplary portion of a roof assembly comprising an exemplary film layer according to this invention; 
           [0033]      FIG. 20  is a perspective view of exemplary overhead console assemblies comprising exemplary film layers according to this invention and various exemplary graphics that may be utilized in connection with various exemplary film layers according to this invention; 
           [0034]      FIG. 21  contains views of portions of exemplary console assemblies comprising exemplary film layers according to this invention and various exemplary graphics that may be utilized in connection with various exemplary film layers according to this invention; and 
           [0035]      FIG. 22  contains representations of various exemplary graphics and an exemplary graphical layout for an exemplary overhead console comprising an exemplary film layer according to this invention. 
       
    
    
     DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS 
       [0036]    It should be understood that the drawings are not necessarily to scale. In certain instances, details that are not necessary for the understanding of the invention or render other details difficult to perceive may have been omitted. It should be understood, of course, that the invention is not necessarily limited to the particular embodiments illustrated herein. 
         [0037]      FIG. 1  illustrates one exemplary embodiment of an overhead console cover  100  usable in an overhead console assembly. As shown in  FIG. 1 , the overhead console cover  100  includes a film  110 . As shown in  FIG. 2 , the film  110  is provided over a supporting substrate  150 . In the exemplary embodiments shown in  FIGS. 1 and 2 , the film  110  includes at least one exemplary embodiment of a functional region  120 . As shown in  FIG. 1 , the functional region(s)  120  can be a button, a button region or a button profile, or a series of buttons, button regions or button profiles. The buttons, button regions or button profiles implemented by the functional regions  120  may be used to actuate any desired function of the vehicle, such as lamp power, Homelink®, and/or other mechanical and/or electrical functions. The film  110  may be made of any material that has the desired characteristics, such as rigidity, moldability and/or flexibility, and through which the desired functions can be performed or actuated. 
         [0038]      FIG. 2  shows a sectional view of a portion of the overhead console cover  100 , including the film  110  and one exemplary embodiment of a functional region  120 . As shown in  FIG. 2 , in various exemplary embodiments, the functional region  120  includes a button region  122  of the film  110  and a rib or extension  162  of a tracer  160 . In various exemplary embodiments, the tracer  160  may be integrated, incorporated and/or inserted into or through the film  110 . In various exemplary embodiments, the tracer  160  can be formed of rubber, silicone or other synthetic and/or rubber-like materials or the like. For example, the tracer  160  can be formed of Santoprene®. In various exemplary embodiments, the plastic or molded material forming the supporting substrate  150  has one or more apertures, recesses or the like  152  provided in it. In various exemplary embodiments, each functional region  120 , and any corresponding tracers  160 , are substantially aligned with the apertures, recesses or the like  152 . 
         [0039]    As further shown in  FIG. 2 , one or more switches, latches or the like  130  are provided behind or in the supporting substrate  150  and aligned with the apertures, recesses or the like  152  and the tracers  160 . In various exemplary embodiments, the tracers  160  may be incorporated or inserted into a mold of a film die. In various exemplary embodiments, at least one tracer  160  is flexibly coupled to the film  110 . It should be appreciated that, although the button region  122  is shown in  FIG. 2  as usable to depress a plunger  132  of the switch  130 , the switch  130  can be replaced with any suitable electrical controller, such as a capacitive switch, proximity switch or the like. 
         [0040]    As shown in  FIGS. 2-5 , in various exemplary embodiments, the film  110  comprises at least one functional region  120  that is separated from other functional regions  120  and/or other areas of the film  110  by at least one slot  124 , which allows additional functional properties or geometries, such as flex. For example, as shown in  FIG. 3 , a functional region  120  has a button region  122  that is coupled to the rest of the film  110  along or about a hinge line  170  and that is separated from the film  110  on all other sides by a slot  124 . It should be appreciated that the flexibility of the button region  122  of the functional region  120  along or about the hinge line  170  can be improved by reducing the thickness of at least a portion of the supporting substrate  150  and/or a portion of the button region  122  and/or the film  110  near the hinge line  170 . As shown in  FIG. 3 , in various exemplary embodiments, first and second ends of the slot  124  help create the pivot point or hinge line  170 , such that the surface of the functional region  120  behaves like a cantilever, with a ridged or fixed end anchored on or about the hinge line  170  of the film  110 . 
         [0041]    The slot  124  may be formed by any material removal or fabrication process including stamping, etching, cutting, molding or casting. The slot  124  may be of any suitable size and configuration. In one embodiment, the slot  124  may be substantially 3 mm wide. The button region  122  of the functional region  120  may also be of any suitable size and configuration. In one embodiment, the button region  122  may be approximately 25 mm wide. 
         [0042]    The tracer  160  may be inserted in the slot  124  such that the rib  162  extends through the slot  124 . In various exemplary embodiments of the present invention, the tracer  160  is inserted into a mold cavity of the film  110 . As shown in  FIG. 4 , in one embodiment, the tracer  160  that outlines a portion of the margin of the button region  122  of the functional region  120  is inserted into the mold cavity of the film  110  and the rib or protrusion  162  is formed and raised at an angle. 
         [0043]    Among other things, the tracer  160  may be utilized to provide a tactile surface. As shown in  FIG. 4 , the tracer  160  may be raised from the surface of the film  110 . For example, the tracer  160  may be substantially 0.8 mm above the surface of the film  110 . The raised nature of the rib  162  of the tracer  160  in relation to the surface of the film  110  allows for tactile feedback to a user and helps define the edges of the button region  122  of the functional region  120 . In another embodiment, however, at least a portion of the tracer  160  may be set below the surface of the film  110 , leaving a recess. Again, the change in elevation between the tracer  160  and the surface of the film  110  provides tactile feedback to the user and helps define the edges of the button region  122  of the functional region  120 . 
         [0044]    It should be appreciated that, by providing tactile feedback to define the edges of the button region  122  of the functional region  120 , the tracer  160  improves the usability of the functional region  120  and allows a user to operate the functional region  120  in low-light or no-light conditions, as well as when the user is not looking directly at the functional region  120 . The tracer  160  may be formed using any suitable material. In various exemplary embodiments, the tracer  160  is formed using a rubber or rubber-type material. In various exemplary embodiments, the tracer  160  is formed using a soft feel material. As shown in  FIG. 5 , a single slot  124  and/or a single tracer  160  extending through the slot  124  may be used to define a single functional region  120  or multiple functional regions  120 . 
         [0045]    Another structure that improves the tactile feedback and edge definition of the functional region(s)  120  is shown in  FIGS. 6-9 . As shown in  FIGS. 6-9 , the film  110 , and at least one functional region  120 , need not be substantially planar. As shown in  FIG. 6 , in various exemplary embodiments, at least one draw or deep recess  140  may be provided in the film  110  to help define at least one functional region  120 . In various exemplary embodiments, a plurality of functional regions  120  may be separated by a number of the draws or deep recesses  140  to help define, at least in part, the shapes of the functional regions  120 . It should be appreciated that a tracer  160 , a plastic cap or the like may be provided between the functional region  120  and the switches  130 . In the exemplary embodiment shown in  FIG. 6 , the tracer  160 , the plastic cap or the like is omitted. 
         [0046]    As shown in  FIG. 7 , in various exemplary embodiments, the functional region  120  may include a popple  126  formed in the film  110 . The popple  126  may be of any suitable size and shape. As shown in  FIG. 8 , in one embodiment, the popples  126  are square or rectangular in shape with a size of 20 to 25 mm square and may be raised 0.25 to 0.5 mm from the otherwise planar surface of the film  110 . As shown in  FIG. 9 , in one embodiment of the present invention, the film  110  may comprise a plurality of popples  126 . The popples  126  may be spaced relatively close together. For example, the popples  126  in one embodiment of the present invention may be spaced apart by 1 mm or less. 
         [0047]    Referring back to  FIG. 7 , the use of poppies  126  is not limited to changing elevations and defining button regions  122 . As such, the film  110  need not include the raised popples  126  shown in  FIGS. 7-9 . Rather, the film  110  may include one or more poppies  128  that are substantially flat, smooth and/or flush with the surface of the film  110  when in their rest state, i.e., when they are not being depressed by a user. In such exemplary embodiments, other structures usable to define the edges of the functional region  120  and/or to provide tactile feedback may be used. 
         [0048]    Other variations of the various exemplary embodiments of the present invention outlined herein may also be used. For example, the film  110  may utilize capacitance switching, proximity sensors or the like. 
         [0049]    Referring to  FIGS. 1-9 , in various exemplary embodiments, the film  110  including the at least one functional region  120  is formed from a single sheet of material. The material may be any substance having suitable rigidity and flexibility characteristics. In various exemplary embodiments, the film  110  is a resilient material such as silicone. The film  110  may also be formed using some other elastomer material. In various exemplary embodiments, at least a portion of the material forming the film  110  will be transparent or translucent, to permit emanation or backlighting. In such exemplary embodiments, the portion of the film  110  which is transparent or translucent may be a thinned portion of the same material forming the rest of the film  110 . In various exemplary embodiments, the material forming the film  110  may be substantially opaque. The film  110  including the at least one functional region  120 , may also be of any suitable thickness. For example, the thickness of the film  110  may range from 0.005-0.030 inches. In various exemplary embodiments, the film  110  may be substantially 0.010 inches in thickness. 
         [0050]    The plastic or molded material used to form the supporting substrate  150  may also be any suitable material. In various exemplary embodiments, the plastic or molded material can include a polycarbonate material. The supporting substrate  150  may also be of any suitable size, shape or configuration. 
         [0051]    As shown in  FIGS. 10-18 , by forming or providing one or more functional regions, such as button regions, lenses and/or bezels into the film, a reduction in cost and complexity of the assembly is achieved. For example, as depicted in  FIGS. 10-14 , various embodiments of the present invention offer a number of advantages, including less tooling, less capital, and fewer part numbers. For example,  FIG. 10  illustrates an exploded view of a traditional overhead console unit. Automobile consoles, including overhead consoles, typically include a protective cover  200  with apertures through or into which at least one button, bezel and/or lens  202  may be fit and be accessible to the user. The buttons may be formed by a variety of manufacturing processes, including stamping and/or injection molding. By incorporating independent buttons, lenses, and/or bezels  212  that are separate from the protective cover  200 , prior art designs require numerous parts and numerous assembly steps to combine the buttons, lenses and/or bezels  202  with the protective cover  200 . 
         [0052]    Referring now to  FIGS. 11-13 , a first exemplary film  210  allows various functional regions or features  220 , such as lenses, bezels and buttons, to be provided as portions of the film  210 . Specifically,  FIG. 11  illustrates an exemplary film  210  having at least one functional region  220 , comprising at least one bezel or bezel appearance  221 , as part of the film  210 . 
         [0053]    Referring to  FIG. 12 , a second exemplary film  210  also has at least one functional region  220 , comprising at least one lens or lens appearance  222 , as part of the film  210 . Referring to  FIG. 13 , a third exemplary film  210  has at least one functional region  220 , comprising at least one bezel or bezel appearance  221 , at least one lens or lens appearance  222 , and at least one button  224 , as part of the film  210 . In comparison, the traditional overhead console units shown in  FIGS. 10 and 14  require a greater number of parts and incur associated costs to create and assemble the additional parts. 
         [0054]    The provision of buttons and/or button regions  224 , bezels and/or bezel appearances  221  and/or lenses and/or lens appearances  222  as part of the film  210 , rather than as elements separate from the film  210 , also generally reduces, if not prevents, liquids, debris and other unwanted matter from entering spaces between the switches and simplifies the cleaning of consoles and other assemblies incorporating such switches. 
         [0055]    In addition, as shown in  FIGS. 15-16 , the use of the films  110  and/or  210  allows the use of a multitude of finishes and graphics on various consoles and automobile components. In various exemplary embodiments, a die is preheated with a desired surface finish such as a metallic finish, an animal grain finish, and any other suitable finish or finishes. In various exemplary embodiments, at least one desired surface finish may be printed onto and/or into the film  110  or  210 . High gloss, low gloss, leather, chrome, textures, patterns, and any number of other finishes and graphics may be used in connection with the various embodiments of the film  110  or  210  according to the present invention. In some exemplary embodiments, some or all of the functional regions  120 , such as the buttons and/or button regions  224 , bezels and/or bezel appearances  220  and/or lenses and/or lens appearances  222 , have graphics thereon or therein for indicating the specific functionality, and/or providing other information associated with the functional regions  120 . In some such embodiments, the graphics on or in the functional regions  120 , such as the buttons and/or button regions  224 , the bezels and/or bezel appearances  220  and/or the lenses and/or lens appearances  222  are backlit. 
         [0056]      FIGS. 17-22  illustrate various ways an exemplary film  110  may be incorporated into a variety of interior features and consoles, including an overhead interior lighting assembly  240 , and a roof assembly  250  or a portion of a roof assembly  250 . As shown in  FIG. 17 , an overhead lighting assembly  240  may incorporate a film  110  having a number of functional regions  120  usable to control and/or activate the lighting features of the overhead lighting assembly  240 . For example, functional regions  120  designed according to any of the above-outlined embodiments and/or according to any separate embodiments, may be incorporated into a portion of the overhead lighting assembly  240  to control and/or activate at least one overhead light. As shown in  FIG. 18 , the overhead lighting assembly  240  may take any desired shape and may comprise any number of separate parts or layers, including being a single piece. 
         [0057]    As shown in  FIG. 19 , exemplary embodiments of a film  110  having a number of the functional regions  120  may be incorporated into a roof assembly  250  or a portion of a roof assembly  250 . The film  110  and functional regions  120  may be designed according to any of the above-outlined embodiments and/or any separate embodiments. By using the exemplary film  110 , additional space may be made available in the roof assembly  250  for other features, such as vanity mirrors, control panels and/or display screens  260 . As shown in  FIG. 20 , the roof assembly  250  may have backlit designs and/or indicia that identify the functional regions  120 . As shown in  FIG. 21 , the functional regions  120  may control aspects of a display screen  260  and/or media displayed on the display screen  260 . It should be appreciated that, as stated above, the functional regions  120  may be used to control any desired aspect of the automobile, including lighting controls, Homelink® controls, media controls, power window controls and/or any other desired electrical control and/or mechanical feature of the automobile. As shown in  FIG. 22 , the functional regions  120  may be defined and/or identified by backlit and/or printed graphics or indicia  121 . 
         [0058]    All exemplary dimensions indicated herein in the specification and drawings are exemplary only and not intended to be limiting. Further, while this invention has been described in conjunction with the exemplary embodiments outlined above, various alternatives, modifications, variations, improvements and/or substantial equivalents, whether known or that are or may be presently foreseen, may become apparent to those having at least ordinary skill in the art. Accordingly, the exemplary embodiments of the invention, as set forth above, are intended to be illustrative, not limiting. Various changes may be made without departing from the spirit or scope of the invention. Therefore, the invention is intended to embrace all known or earlier developed alternatives, modifications, variations, improvements and/or substantial equivalents.