OVERHEAD CONSOLE

CROSS-REFERENCE TO RELATED PATENT APPLICATIONS

[0001] This application claims the benefit under 35 U.S.C. 119(e) of U.S. Provisional Application No. 60/907,839, having a riling date of April 19, 2007, titled "Overhead Console Including Buttons and Method of Assembling Overhead Console," the complete disclosure of which is hereby incorporated by reference.

BACKGROUND

[0002] The present disclosure relates generally to an overhead console and to methods of manufacturing such an overhead console. The present disclosure more specifically relates to an overhead console having at least one user interface (e.g., button, switch, control, etc.) and to methods of supporting the user interface within the overhead console.

[0003] Overhead consoles can provide storage compartments in a forward portion of a vehicles for storing items, such as sunglasses, remote control devices, hand-held portable phones and wireless communication devices, etc. Overhead consoles can also provide a support structure for one or more functional devices that may find utility within the vehicle (e.g., overhead task lights, display screens, HVAC equipment, etc.). To operate these functional devices, the overhead console may further include one or more user interfaces that are configured to be selectively actuated by a user. There continues to be a need to improve the configuration of such user interfaces within an overhead console and/or to improve the assembly of an overhead console having user interfaces.

SUMMARY

[0004] One embodiment relates to an overhead console for a vehicle. The overhead console comprises a housing defining at least one opening and having a first connecting element. The overhead console also comprises a user interface configured to be received by the at least one opening. The user interface has a biasing element and a second connecting element. The biasing element is integrally formed with the user interface as a one-piece member. The second connecting element is configured to engage the first connecting element to allow the user interface to move relative to the housing between a first position and a second position. The overhead console further comprises a first platform received by the housing and configured to retain the engagement of the first connecting element and the second connecting element. The biasing element is configured to apply a force against the first platform to bias the user interface towards the first position and against the housing.

[0005] Another embodiment relates to an overhead console for a vehicle. The overhead console comprises a housing defining a plurality openings and having a first connecting element associated with each opening. The overhead console also comprising a plurality of user interfaces configured to be received by the plurality of openings. The user interfaces each have a second connecting element configured to engage the first connecting element to allow the user interface to move relative to the housing between a first position and a second position. The overhead console further comprises a one-piece platform received by the housing and configured to retain the engagement of each of the first connecting elements and the second connecting elements.

[0006] Another embodiment relates to a method of assembling an overhead console for a vehicle. The method comprising providing a housing defining a plurality of openings and having a first connecting element associated with the openings. The method also includes inserting a plurality of user interfaces into the openings. The user interfaces each have a biasing element and a second connecting element that engages the first connecting element to allow the user interfaces to rotate relative to

the housing between an at rest position and an actuation position. The method further comprises covering the plurality of user interfaces with a bracket to retain the engagement of the first connecting elements and the second connecting elements. The bracket provides a light guide for each user interface. The method further comprises providing a light source over the light guides. The biasing elements are configured to act on the first platform to bias the user interfaces toward the at rest position.

BRIEF DESCRIPTION OF THE DRAWINGS

[0007] FIGURE 1 is an isometric view of a vehicle including an overhead console according to an exemplary embodiment.

[0008] FIGURE 2 is a partial planar view of an overhead console according to an exemplary embodiment.

[0009] FIGURE 3 is an exploded isometric view of the overhead console of FIGURE 2.

[0010] FIGURE 4 is an isometric view of a housing of the overhead console of FIGURE 2 shown according to an exemplary embodiment.

[0011] FIGURE 5 is an isometric view of a user interface of the overhead console of FIGURE 2 shown according to an exemplary embodiment.

[0012] FIGURE 6 is an isometric view of the housing of FIGURE 4 shown supporting the user interface of FIGURE 5.

[0013] FIGURE 7 is a detailed isometric view of the combination shown in FIGURE 6.

[0014] FIGURE 8 is an isometric view of the housing of the FIGURE 4, the user interface of FIGURE 5 and a first platform shown according to an exemplary embodiment.

[0015] FIGURE 9 is an isometric view of the housing of the FIGURE 4, the user interface of FIGURE 5, the first platform of FIGURE 8 and a second platform shown according to an exemplary embodiment.

[0016] FIGURE 10 is a cutaway isometric view of the overhead console of FIGURE 1.

[0017] FIGURE 11 is a partial cross-sectional view of the overhead console of FIGURE 10 taken through a biasing member of the user interface.

[0018] FIGURE 12 is a partial cross-sectional view of the overhead console of FIGURE 10 taken through a pivot shaft of the user interface.

[0019] FIGURE 13 is an exploded isometric view of an overhead console according to another exemplary embodiment.

[0020] FIGURE 14 is a partial cross-sectional view of the overhead console of FIGURE 13 taken through a pivot shaft of the user interface.

DETAILED DESCRIPTION

[0021] FIGURES 1 through 14 illustrate exemplary embodiments of a component or assembly, shown as an overhead console 100, for use in a vehicle (e.g., automobiles such as cars, trucks, sport utility vehicles, minivans, buses, and the like; airplanes, boats, etc.). The overhead console 100 may be installed at any suitable location within a vehicle and integrated with any other vehicle accessories. The overhead console 100 may be provided in a wide variety of sizes, shapes, and configurations, and made from a wide variety of materials and manufacturing processes according to various exemplary embodiments. AU such variations are intended to be within the scope of the inventions.

[0022] Referring to FIGURE 1, the overhead console 100 is shown with a vehicle 10 according to an exemplary embodiment. The overhead console 100 is located in an interior of the vehicle 10 centrally between a front driver seat and a front passenger

seat. The overhead console 100 may be supported by a roof frame of the vehicle 10 and/or by one or more other support structures (e.g., headliner assembly, sub-frame, roof panel, etc.). As detailed below, the overhead console 100 includes at least one user interface (e.g., button, switch, control, etc.) that is configured to be selectively actuated by a vehicle occupant to control a functional device (e.g., overhead task lights, entertainment systems, navigation systems, communication systems, HVAC systems, etc.) within the vehicle 10. The one or more user interfaces are supported within the overhead console 100 in a manner that provides for a relatively low-profile and easy to manufacture overhead console.

[0023] Referring to FIGURE 2, the overhead console 100 is shown according to an exemplary embodiment. According to the embodiment illustrated, the overhead console 100 includes a plurality of user interfaces (e.g., controls, switches, etc.), shown as buttons 140. In particular, the overhead console 100 is shown as including eight buttons 140, three buttons at a first lateral side (e.g., a driver's side, etc.) of the overhead console 100, three buttons on an opposite second lateral side (e.g., a passenger's side, etc.) of the overhead console 100 and two buttons at a longitudinal end (e.g., a rearward end, etc.) of the overhead console 100. The buttons 140 are configured for a variety of tasks including controlling overhead task lights 102 (e.g., map lights, etc.), other interior lights, short range radio communication equipment (e.g., Bluetooth®, Homelink®, etc.) and/or any other functional device.

[0024] Referring to FIGURE 3, an exploded view of the overhead system 100 is shown. In addition to buttons 140, the overhead system 100 generally includes a support member (e.g., base, body, housing, cover, trim piece, etc.), shown as a bezel 120, a first platform (e.g., panel, plate, retaining member, clamping member, etc.), shown as a bracket 160, and a second platform (e.g., panel, plate, illumination device support member, etc.), shown as a circuit board 180. The bezel 120, the buttons 140, the bracket 160 and the circuit board 180 cooperate to provide for a relatively low- profile and easy to manufacture overhead console. The housing 120 is configured to support the buttons 140 in a moveable (e.g., rotatable, pivotable, etc.) manner, while the bracket 160 is configured to retain or trap the buttons 140 within the bezel 120.

The circuit board 180 is configured to supported circuitry, electronics and/or components associated with the buttons 140 and/or functional devices on the overhead console 100.

[0025] Referring to FIGURE 4, the bezel 120 is shown according to an exemplary embodiment. The bezel 120 provides a trim piece or member having an exposed side (e.g., outer side, etc.) that is configured to generally face the vehicle interior and to at least partially conceal, and to improve the aesthetic appearance of, the overhead console 100 when viewed from an interior portion (e.g. cabin, etc.) of the vehicle 10. The bezel 120 also has a concealed side (e.g., inner side, etc.) that provides suitable attachment structures (e.g. apertures, clips, bosses, etc.), shown as fastening openings 122, for mounting the overhead console 100 to the vehicle roof or an intermediate structure (e.g., base, etc.) coupled thereto.

[0026] The bezel 120 defines one or more openings (e.g., apertures, etc.), shown as sockets 124, that are configured to receive the buttons 140. Each socket 124 may be configured to receive more than one button 140 (as shown), or alternatively, may be configured to receive a single button 140. If the socket 124 is configured to receive more than one button 140, one or more separators 126 (e.g., dividers, projections, etc.) may extend into the sockets 124 to visually and/or functionally separate the buttons 140 that share a common socket 124. The bezel 120 may also define additional openings for receiving components including, but not limited to, overhead lamps, display panels, speakers, storage compartments, etc.

[0027] The bezel 120 also includes connecting element or mounting structure (e.g., extensions, projections, flanges, recesses, etc.) for supporting the one or more buttons 140 in a moveable manner relative to the bezel 120. The mounting structure is provided on the concealed side of the bezel 120 near (e.g., closely adjacent, etc.) to the socket 124 in which the button 140 is received. Each button 140 may include its own mounting structure, or alternatively, a common mounting structure may be shared between one or more of the buttons 140. For larger buttons 140, more than one mounting structure may be provided to support the buttons in a suitable manner.

[0028] According to the embodiment illustrated, the mounting structure includes a first projection 128 (e.g., boss, pivot cradle, etc.) and a second projection 130 (e.g., boss, pivot cradle, etc.) that upwardly extend from a body portion of the bezel 120. The first projection 128 and the second projection 130 are spaced apart from and generally aligned with each other. Each of the first projection 128 and the second projection 130 include a recess 132 (e.g., depression, groove, channel, slot, etc.) in a surface that generally faces the other projection. The recesses 132 are configured to receive a portion of the button 140 in a manner that allows the button 140 to move relative to the bezel 120. According to an exemplary embodiment, the first projection 128 and the second projection 130 cooperate to provide a cradle for the button 140, which allows the button 140 to rotate relative to the bezel 120 about a pivot defined by the recesses 132. In such an embodiment, the bottom of the recesses 132 may be contoured (e.g., curved, circular, etc.) to improve the rotatable movement of the button 140.

[0029] The bezel 120 may also include suitable structure (e.g. contours, recesses, bosses, brackets, etc.) for mounting or containing other structure or components useful with the vehicle interior (e.g., storage compartments, latches, instruments, illumination devices, etc.). The bezel 120 may be coupled to an internal structure of the vehicle (e.g. overhead structure, panel, floor, instrument cluster, center stack, etc.) by suitable connecting devices (e.g., mounting tabs, clips, pushnuts, bolts, rivets, etc.) configured to engage corresponding apertures located on a structure of the vehicle interior. According to an exemplary embodiment, the bezel 120 is made from plastic by a molding process and may be provided in any suitable color to accent a color scheme for the vehicle interior.

[0030] Referring to FIGURE 5, a single button 140 is shown according to an exemplary embodiment. The button 140 is configured to move relative to the bezel 120 between a first position (e.g., off position, rest position, etc.) and a second position (e.g., on position, actuation position) for actuating or otherwise controlling a functional device within the vehicle 10 (e.g., an overhead task lamp within the overhead console 100, etc.). According to an exemplary embodiment, the button 140

is configured to be manipulated by a vehicle occupant between the first position and the second position by being pressed or pushed (e.g., a push-button, etc.).

[0031] According to the embodiment illustrated, the button 140 includes a body portion 142, an extension (e.g., projection, ledge, tab, etc.), shown as a flange 144, a mounting structure (e.g., fastening element, etc.), shown as a pivot shaft 146, a biasing element (e.g., spring, retainer, etc.), shown as preload finger 148 and an actuation member (e.g., projection, etc.), shown as a post 150. The body portion 142, the flange 144, the pivot shaft 146, the preload finger 148 and the post 150 may be integrally formed as a one-piece member (as shown), or alternatively, one or more of the body portion 142, the flange 144, the pivot shaft 146, the preload finger 148 and the post 150 may be a separate component that is subsequently coupled to the button 140.

[0032] Still referring to FIGURE 5, the body portion 142 is the portion of the button 140 that is configured to be engaged (e.g., pressed, pushed, etc.) by a vehicle occupant. According to the embodiment illustrated, the body portion 142 is contoured to extend downward towards the interior of the vehicle 10. The contour of the body portion 142 may be used as a light block or light guide to assist in capturing and guiding light towards the button 140. A lowermost portion 154 of the body portion 142 may include a lens and/or indicia to assist in directing a vehicle occupant to the button 140 by allowing backlighting to pass therethrough.

[0033] The flange 144 outwardly extends from an outer periphery of the body portion 142 and may be configured to function as a stop member for the button 140 (e.g., to restrict the movement of the button 140 relative to the bezel 120, etc.) and/or as a light block member for the button 140 (e.g., to prevent backlighting associated with the button 140 from leaking or escaping from the button 140). Upwardly extending from the flange 144 is a stop member, shown as a projection 156, that is configured to limit the movement of the button 140 as the button 140 moves towards the second or actuation position.

[0034] The pivot shaft 146 includes free ends that are configured to engage the recesses 132 of the first projection 128 and the second projection 130 on the bezel 120, and defines the axis about which the button 140 is configured to rotate. According to the embodiment illustrated, the pivot shaft 146 includes a cross-section that is substantially circular. According to the various alternative embodiments, the pivot shaft 146 may have any of a number of configurations, including being provided as a separate member.

[0035] The preload finger 148 is coupled to the pivot shaft 146 and has a free end configured to engage the bracket 160. Engagement between the preload finger 148 and the bracket 160 may be used to bias the button 140 into the first position and/or may be used to help reduce noise (e.g., rattle, etc.) within the overhead console 100. Referring to FIGURES 10 through 12, cross-sectional images of the overhead console 100 are shown. As shown in these FIGURES, the preload finger 148 has a first end 157 that is coupled to the button 140. According to the embodiment illustrated, the first end 157 is coupled to the button 140 by being integrally formed with the pivot shaft 146. The preload finger 148 includes a spring arm 158 (e.g., segment, member, etc.) that is supported in a cantilever manner relative to the pivot shaft 146 at the first end 157. Upwardly extending from an opposite end of the spring arm 158 is a tab 159 that is configured to engage the bracket 160. According to an exemplary embodiment, the tab 159 extends upward at an orientation that is generally perpendicular to the spring arm 158. Such a configuration allows the preload finger 148 to deflect or rotate about the first end 157.

[0036] During operation, the preload finger 148 biases the button 140 towards the first or at rest position by having the tab 159 preloaded against a projection 176 on the bracket 160. The biasing of the button 140 against the bezel 120 towards the first position reduces the noise or rattle of the buttons 140 caused by the buttons 140 shaking in the sockets 124 and vibrating against the bezel 120. When a force is applied to the button 140 (e.g., when a vehicle occupant presses the button 140, etc.) an amount sufficient to overcome the biasing force of the preload finger 148, the spring arm 158 rotates downward relative to the first end 157 as the tab 159 continues

to engage the projection 176. When the force is removed from the button 140, the button 140 returns to the first or at rest position.

[0037] Referring back to FIGURE 5, the post 150 upwardly extends from the body portion 142 and/or the flange 144 and is configured to actuate a switching device or sensor associated with the button 140. As such, the post 150 provides for the mechanical actuation of the switching device. According to the various alternative embodiments, actuation of the switching can be achieved electrically, for example, by using a capacitive sensing system.

[0038] Referring to FIGURES 6 and 7, the buttons 140 are shown as being received by the sockets 124. According to an exemplary embodiment, the buttons 140 are inserted (e.g., dropped, etc.) into the sockets 124 from the concealed side of the bezel 120 (e.g., back-loaded, etc). The flanges 144 at least partially extend over and engage a shoulder area on the bezel 120 to prevent the buttons 140 from falling through the sockets 124. The pivot shafts 146 reside in the recesses 132 to allow for the rotation of the buttons 140. To help locate or align the positioning of the buttons 140 on the bezel 120, the button 140 is shown as including an aperture or slot 152 that is configured to receive a projection or rib 134 provided on the bezel 120. The buttons 140 are arranged so that both the preload fingers 148 and the post 150 are extending in an upward direction. According to the embodiment illustrated, the pivot shafts 146 of the buttons 140 are all supported along an inner portion of the bezel 120 such that each button 140 is configured to rotated towards the center of the overhead console 100. According to the various alternative embodiments, the buttons 140 may be configured to rotate at any of a number of orientations relative to the overhead console 100.

[0039] Referring to FIGURE 8, the bracket 160 is shown as being received by the bezel 120. The bracket 160 is provided in a suitable shape and contour for assembly to the bezel 120 and to retain (e.g. hold, capture, clamp, sandwich, etc.) the buttons 140 in position on the bezel 120. According to the embodiment illustrated, the bracket 160 is a one-piece member having a size generally configured to cover all of

the buttons 140. The bracket 160 includes connection devices 162 and is assembled (e.g. fixed, secured, mounted, etc.) to the bezel 120 by connectors (e.g., mounting tabs, clips, pushnuts, bolts, rivets, etc.) configured to engage the connection devices 162 on the bracket 160 and suitable connecting structure on the bezel 120. The bracket 160 is positioned on the bezel 120 so that assembly of the bezel 120, the buttons 140 and the bracket 160 retains the buttons 140 in the recesses 132 while providing a biasing force on the buttons 140.

[0040] Referring again to FIGURES 10 through 12, the bracket 160 is shown as including a substantially flat body portion 164 having a first surface 166 configured to face the bezel 120 and an opposite second surface 168 configured to face away from the bezel 120. Extending through the body portion 164 are one or more openings 170 that are configured to be generally aligned with the body portions 142 of the buttons 140. Openings 170 may allow light emanating from an illumination device (e.g., light emitting diode, etc.) positioning behind the bracket 160 to reach the buttons 140 and/or may provide a passageway through which the buttons 140 can actuate (e.g., mechanically, etc.) a switch positioned behind the bracket 160.

[0041] Still referring to FIGURES 10 through 12, provided at the first surface 166 is a retaining member (e.g., tab, rib, edge, etc.), shown as a first projection 172, to hold (e.g. capture, sandwich, restrain, etc.) the pivot shaft 146 within the recesses 132, a light conduit (e.g., e.g., light block, guide, etc.), shown as a second projection 174, to guide light towards the button 140 and/or prevent light from leaking or escaping into other areas of the overhead console 100, a biasing force member (e.g., tab, rib, edge, etc.), shown as a third projection 176, to provide a surface for the preloaded finger 148 of the button 140 to act upon for biasing the button 140 towards the first position, and a stop member (e.g., tab, rib, edge, etc.), shown as a fourth projection 178, to restrict the movement of the button 140 as the button is move towards the second position. Provided at the second surface 168 is a corresponding light conduit (e.g., e.g., light block, guide, etc.), shown as a fifth projection 179, to further guide light towards the button 144 and/or prevent light from leaking or escaping into other areas of the overhead console 100. The second projection 174 and the fifth projection 179

are both in the form of walls that substantially surround (e.g., enclose, encircle, etc.) the opening 170 and cooperate to define a conduit (e.g., chamber, etc.) with a first open end at or near an illumination device and a second open end at or near the button 140.

[0042] Referring to FIGURE 9, the circuit board 180 is shown as being received by the bezel 120. The circuit board 180 provides a surface to which circuit components associated with the overhead console 100 or any other structure within the vehicle are coupled. According to the embodiment illustrated, the circuit board 180 supports one or more illumination devices, shown as a lamp 182 in FIGURES 10 and 12, and one or more switch devices (e.g., sensor, etc.), shown as a switch 184 in FIGURE 11. The lamp 182 is generally aligned with an open end of the fifth projection 179 so that light emanating from the lamp 182 can be guided towards the button 140 to provide backlighting for the button 140 and/or to illuminate indicia on or around the button 140. The switch 184 is generally aligned with an upper end of the post 150 so that the post 150 will engage the switch 184 when the button 140 is pressed by a vehicle occupant.

[0043] According to one exemplary embodiment, the lamp 182 is a light emitting diode (LED) and the circuit board 180 includes LEDs aligned with each of the buttons 140. The flanges 144 extending from the buttons overlap with the bezel and provide a light block which substantially prevents light from escaping around the edges of the buttons. The inner bracket may also include generally vertical walls that are aligned with the LEDs and provide an additional light block. Each button 140 may include a stylized opening with a clear portion or lens that is illuminated by the LED. According to various exemplary embodiments the lens may be formed from a generally clear material or a colored translucent or transparent material. The lens may be a simple geometric shape or a more complex shape such as an illustration of a light bulb or a word.

[0044] The circuit board 180 may also be used to support additional illumination devices, shown as overhead task lamps 186 in FIGURE 2, to illuminate an interior

portion of the vehicle 10. According to the various alternative embodiments, the circuit board 180 may be used to support any of a number of various functional devices (e.g., overhead task lights, entertainment systems, navigation systems, communication systems, HVAC systems, etc.) that may find utility within the overhead console 100.

[0045] Referring now to FIGURES 13 and 14, an overhead console 100 is shown according to another exemplary embodiment. The overhead console 100 is similar to the previously described exemplary embodiment except the button 140 does not include an outwardly extending flange 144 to provide a physical stop and a light block. Instead, the button 140 includes two outwardly extending arms 145 or protrusions that are received by the bezel 120 in two corresponding apertures (e.g., hollows, sockets, etc.), shown as recesses 133. A light block or guide is provided by a wall or projection 147 extending upward from the button 140 that cooperates with the one or more walls or projections 174, 179 extending from the bracket 160 as shown in FIGURE 14. The button 140 also lacks a biasing member and relies on gravity or a preload condition between the circuit board 180 and the button 140 to return it to a first or at rest position when a user releases pressure on the button 140.

[0046] It is important to note that the construction and arrangement of the of the various embodiments of the overhead console and method supporting a user interface within an overhead console provided herein is illustrative only. Although only a few exemplary embodiments of the present inventions have been described in detail in this disclosure, those skilled in the art who review this disclosure will readily appreciate that many modifications are possible in these embodiments (such as variations in shape and size of the housing, user interfaces, first platform and second platform; location, orientation or positioning of the user interfaces; different types of functional devices supported by or integrated into the overhead console; various locations for mounting within the vehicle; location, configuration and engagement patterns of the mounting surfaces and mounting structure, etc.) without materially departing from the novel teachings and advantages of the inventions. Further, elements shown as integrally formed may be constructed of multiple parts or elements, the position of

elements may be reversed or otherwise varied, and the nature or number of discrete elements or positions may be altered or varied. Further, the overhead console and method supporting a user interface within an overhead console may be used in any type of vehicle such as trucks, recreational vehicles, minivans, sport utility vehicles, passenger automobiles, etc. and at any suitable location within the vehicle. Accordingly, all such modifications are intended to be within the scope of the invention as defined in the appended claims.

[0047] The order or sequence of any process or method steps may be varied or re- sequenced according to alternative embodiments. In the claims, any means-plus- function clause is intended to cover the structures described herein as performing the recited function and not only structural equivalents but also equivalent structures. Other substitutions, modifications, changes and omissions may be made in the design, operating configuration and arrangement of the preferred and other exemplary embodiments without departing from the spirit of the inventions as expressed in the appended claims.