VEHICLE INTERIOR TRIM PART, METHOD FOR MANUFACTURING THE TRIM PART AND VEHICLE COMPRISING THE INTERIOR TRIM PART

Abstract

The present disclosure is directed to an interior trim part of a vehicle which includes a carrier with a first surface, a second surface, and at least one opening penetrating the carrier from the first surface to the second surface, a membrane layer applied to the first surface and covering the opening, a décor layer applied to the membrane layer, an electronic module arranged within the opening and detachably contacting the membrane layer, and a vibration generating element either integrated into the electronic module or interacting with the electronic module such that vibrations generated by the vibration generating element are transferred to the membrane layer and the décor layer. Moreover, the present disclosure is directed to a vehicle comprising such an interior trim part and a method for manufacturing such an interior trim part.

Claims

1. An interior trim part of a vehicle, comprising a carrier having a first surface, a second surface, and at least one opening penetrating the carrier from the first surface to the second surface, a membrane layer applied to the first surface and covering the opening, a décor layer applied to the membrane layer, and an electronic module detachably arranged within the opening and contacting the membrane layer or interacting with the membrane layer.

2. The interior trim part according to claim 1, wherein the carrier is molded on the membrane layer or vice versa.

3. The interior trim part according to claim 1, wherein the membrane layer is fastened to the first surface of the carrier by a first adhesive layer.

4. The interior trim part according to claim 1, wherein the décor layer is applied to the membrane layer by a second adhesive layer.

5. The interior trim part according to claim 1, wherein the membrane layer has a thickness of between 0, 05 mm and 4 mm.

6. The interior trim part according to claim 1, wherein the décor layer has a thickness (TD) of between 0, 2 mm and 4 mm.

7. The interior trim part according to claim 1, wherein the electronic module is fastened to the carrier by a screw- or snapping connection.

8. The interior trim part according to claim 1, wherein at least one vibration generating element is either integrated into the electronic module or interacting with the electronic module such that vibrations generated by the vibration generating element are transferred to the membrane layer and the décor layer.

9. The interior trim part according to claim 1, wherein the electronic module is decoupled from the carrier by dampening elements.

10. The interior trim part according to claim 1, wherein a housing is fastened to the carrier, said housing is enclosing the electronic module.

11. A vehicle, comprising an interior trim part according to claim 1.

12. A method for manufacturing an interior trim part according to claim 1, comprising the following steps: producing the carrier by over molding the membrane layer such that the membrane layer and the carrier are fastened to each other or injection molding the carrier followed by the steps of applying a first adhesive layer to the first surface and fastening the membrane layer to the carder.

13. The method according to claim 12, comprising the following steps: placing a lamination tool such that it is contacting the second surface and the membrane layer, laminating the décor layer on the membrane layer.

14. The method according to claim 13, wherein the step of laminating the décor layer on the membrane layer comprises the step of applying a second adhesive layer on the membrane.

15. The method according to claim 12, comprising the following step: fastening the electronic module to the carrier by a screw- or snapping connection.

16. The method according to claim 12, comprising the following step: fastening a housing to the carrier such that the housing is enclosing the electronic module.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0051] Other features and advantages of the present invention will be more readily apparent upon reading the following description of currently preferred exemplified embodiments of the invention with reference to the accompanying drawing, in which:

[0052] FIG. 1 shows an interior trim part according to the cited prior art,

[0053] FIG. 2 shows a first embodiment of an interior trim part of the present invention,

[0054] FIGS. 3A to 3E shows different steps of a method for manufacturing a second embodiment of the interior trim part of the present invention,

[0055] FIGS. 4A and 4B shows a third embodiment of the interior trim part according to the present disclosure in two different states, and

[0056] FIG. 5 shows a vehicle comprising at least one trim part according to the present invention, all of the Figures being principle sketches.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

[0057] Throughout all the Figures, same or corresponding elements are generally indicated by same reference numerals.

[0058] Turning now to the drawing, and in particular to FIG. 1, there is shown an interior trim part 10 for or of a vehicle 12 (see FIG. 4) according to the state of the art, resembling the interior trim part 10 disclosed in DE 10 2018 131 978 A1, is illustrated by means of a principle drawing.

[0059] The interior trim part 10 comprises a carrier 14 with a first surface 16 and a second surface 18. Moreover, an opening 20 is penetrating the carrier 14 from the first surface 16 to the second surface 18. An electronic module 22 is arranged within the opening 20 which is fastened to the carrier 14 via the second surface 18 by means of a screw connection 24. Moreover, a housing 23 is fastened to the carrier 14, also by means of a screw connection 24. Both the electronic module 22 and the housing 23 are fastened to the carrier 14 with dampening elements 26 arranged between the second surface 18 and the electronic module 22 or the housing 23, respectively.

[0060] The electronic module 22 is interacting with a vibration generating element 28, which upon activation is generating vibrations. The vibration generating element 28 is located between the housing 23 and the electronic module 22. However, it is also possible that the vibration generating element 28 is Integrated into the electronic module 22.

[0061] The electronic module 22 is arranged inside the opening 20 such that its top surface 29 is more or less flush with the first surface 16 of the carrier 14. A gluing layer 30 is applied to the first surface 16 and the top surface 29. A décor layer 32 is applied to the first surface 16 and the top surface 29 by means of the gluing layer 30. This means that the electronic module 22 is fastened to the décor layer 32.

[0062] A user, in particular a driver or a passenger of the vehicle 12, may trigger a function provided or activated by the electronic module 22 by pressing the décor layer 32 in the area of the opening 20 with his fingers. To identify this area the décor layer 32 may be illuminated and/or may comprise a marking. Depending on the design of the electronic module 22 the user may only have to touch the décor layer 32 within the area of the opening 20 or has to apply a certain pressure within this area for activating the electronic module 22. The vibration generating element 28, for example embodied as an exciter or activator, is triggered once the electronic module 22 is activated. The vibrations are transmitted to the décor layer 32 and thus perceptible by the user, thereby providing a haptic feedback.

[0063] However, due to the movement of the décor layer 32 induced by the vibrations the edges of the opening 20 may become visible with the time. Due to height tolerances an offset may form between the carrier 14 and the first surface 29 of the electronic module 22 leading to a gap in the connection to the décor layer 32. This gap will become visible with the time.

[0064] Beyond that the section of the décor layer 32 covering the opening 20 may bend leading to an unpleasant appearance of the visible side of the interior trim part 10.

[0065] As mentioned, the electronic module 22 is fastened to the décor layer 32 by means of the gluing layer 30. As a consequence the electronic module 22 cannot be removed in case of failure or update without damaging the décor layer 32. In the worst case the entire interior trim part 10 has to be changed.

[0066] In FIG. 2 a first embodiment of the inventive interior trim part 34.sub.1 is demonstrated by means of a principle drawing. The basic design of the inventive interior trim part 34.sub.1 is the same as described for the interior trim part 34.sub.1 according to the prior art. Thus, only the key differences are described in the following.

[0067] In the first embodiment of the inventive interior trim part 34.sub.1 a membrane layer 36 is applied to the first surface 16 of the carrier 14. The membrane layer 36 is also covering the opening 20. The membrane layer 36 is fastened on the first surface 16 by means of a first adhesive layer 38, however, other ways of fastening the membrane layer 36 to the carrier 14 are possible, e.g. by over molding the carrier 14 to the membrane layer 36.

[0068] The first adhesive layer 38, however, is only applied to the first surface 16 of the carrier 14, but not inside the opening 20. In other words, there is no permanent connection between the electronic module 22 and the membrane layer 36. However, the membrane layer 36 and the electronic module 22 are arranged relative to each other such that they can interact with each other regarding the transmission of vibrations generated by the vibration generating element 28.

[0069] A second adhesive layer 40 is applied on the membrane layer 36 to fasten the décor layer 32 on the membrane layer 36. When the user touches the décor layer 32 within the area of the opening 20 and activates the electronic module 22 the vibrations generated by the vibration generating element 28 are transferred from the electronic module 22 to the membrane layer 36 and further to the décor layer 32. For this purpose the top surface 29 of the electronic module 22 may touch the membrane layer 36 or only a small gap is formed between the top surface 29 and the membrane layer 36.

[0070] The membrane layer 36 has a thickness TM of between 0, 05 mm and 4 mm. The décor layer 32 has a thickness TD of between 0, 2 mm and 4 mm.

[0071] The membrane layer 36 avoids that the vibrations make the edges of the openings 20 visible on the visible side of the décor layer 32. Further, the membrane layer 36 compensates gaps in the connection to the décor layer 32 caused by size tolerances of the electronic module 22 relative to the carrier 14. Moreover, as there is no permanent connection between the electronic module 22 and the membrane layer 36, the electronic module 22 can be replaced without damaging the interior trim part 34.sub.1. In case the electronic module 22 needs to be replaced, there is no need to replace the interior trim part 34.sub.1 as well.

[0072] FIGS. 3A to 3E show the most important steps of a method for producing a second embodiment of the interior trim part 34.sub.2. First of all the membrane layer 36 is provided and then the carrier 14 is molded over the membrane layer 36 (FIG. 3A). Depending on the material of the membrane layer 36 there is no need to use glue or other fastening means to connect the membrane layer 36 and the carrier 14 with each other. Therefore and in contrast to the first embodiment of the interior trim part 34.sub.1, the interior trim part 34.sub.2 according to the second embodiment does not comprise the first adhesive layer 38.

[0073] As evident from FIG. 3B a lamination tool 42 is arranged such that it contacts the second surface 18 of the carrier 14 and the membrane layer 36. After that the second adhesive layer 40 is applied to the membrane layer 36 and the décor layer 32 is fastened to the membrane layer 36 and thus to the carrier 14. The lamination tool 42 ensures that the required pressure can be applied across the entire décor layer 32 including the area of the opening 20.

[0074] After that the lamination tool 42 is removed and the electronic module 22 is fastened to the carrier 14, in this case by a screw connection 24. It is noted that dampening elements 26 are arranged between the electronic module 22 and the second surface 18 of the carrier 14. In case the dampening elements 26 are integrated into the electronic module 22 it is not necessary to provide the dampening elements 26 as shown.

[0075] In the last step the housing 23 is mounted to the carrier 14. As in the case of the electronic module 22, also in the case of the housing 23 dampening elements 26 are placed within the fastening sections of the electronic module 22 and the carrier 14. With the housing 23 the vibration generating element 28 is mounted. The housing 23 acts as a support for the vibration generating element 28.

[0076] The dampening elements 26 decouple the electronic module 22 and the housing 23 from the carrier 14 with respect to the transmission of the vibrations. The majority of the vibrations are transmitted to the décor layer 32 via the top surface 29 of the electronic component.

[0077] In FIGS. 4A and 4B a third embodiment of the interior trim part 34.sub.3. The constitution of the interior trim part 34.sub.3 of the third embodiment is to a large extent identical to the interior trim part 34.sub.2 of the second embodiment. Therefore, only the essential differences are addressed below. In contrast to the first and second embodiment of the trim part 34.sub.1, 34.sub.2, in the third embodiment of the trim part 34.sub.3 the electronic module 22 is not fastened to the carrier 14 but supported on the vibration generating element 28. Further, the electronic module 22 is in contact with the membrane layer 36. Due to this arrangement the use of dampening elements 26 can be avoided. The vibration generating element 28 is designed not only to create vibrations but also to be moved between a retracted position (see FIG. 4A) and an expanded position (FIG. 48). In an embodiment not shown two separate actuation devices may be provided. One actuation device may be used for the generation of vibrations and one actuation device for moving the electronic module 22 between the retracted position and the expanded position. Beyond that, it may be possible to provide several vibration generating elements 28, e.g., one vibration generating element 28 for generating vibrations in the retracted position and one in the expanded position. For enhancing the haptic feedback one may also employ a plurality of vibration generating elements 28.

[0078] It Is also possible to dispense with the creation of vibrations and only expand and retract the vibration generating element 28.

[0079] In the expanded position the membrane layer 36, the second adhesive layer 40 and the décor layer 32 are deformed such that an elevation is generated in the area of the opening 20. This elevation is just big enough to be perceptible by the user who touches the décor layer 32 in the area of the opening 20. The material the membrane layer 36, the second adhesive layer 40 and the décor layer 32 are made of is chosen to be flexible enough to allow a reversible deformation such that the décor layer 32 returns in a flat state once the vibration generating element 28 is moved in its retracted position (FIG. 4A). This reversible deformation is also referred to as “morphing”.

[0080] FIG. 5 shows principle top view of a vehicle 12 which comprises a number of interior trim parts 34 according to the present invention. Arm rests 44 and instrument panels 46 are named as non-exhaustive examples of such interior trim parts 34.

[0081] While the invention has been illustrated and described as embodied in a vehicle trim part, it is not intended to be limited to the details shown since various modifications and structural changes may be made without departing in any way from the spirit of the present invention. The embodiments were chosen and described in order to best explain the principles of the invention and practical application to thereby enable a person skilled in the art to best utilize the invention and various embodiments with various modifications as are suited to the particular use contemplated.

[0082] What is claimed as new and desired to be protected by Letters Patent is set forth in the appended claims and their equivalents: