U.S. patent application number 10/711652 was filed with the patent office on 2006-03-30 for automotive ashtray having an electroluminescent lamp and method of making the same.
Invention is credited to Alan G. Dry, Bogdan Radu.
Application Number | 20060066119 10/711652 |
Document ID | / |
Family ID | 36084520 |
Filed Date | 2006-03-30 |
United States Patent
Application |
20060066119 |
Kind Code |
A1 |
Radu; Bogdan ; et
al. |
March 30, 2006 |
AUTOMOTIVE ASHTRAY HAVING AN ELECTROLUMINESCENT LAMP AND METHOD OF
MAKING THE SAME
Abstract
An automotive ashtray comprises a compartment body defining a
cavity and having an opening for accessing the cavity. The
compartment body includes a first connecting member integrally
formed therein. The ashtray further includes a cover having a
second connecting member integrally formed therein, the first
connecting member cooperating with the second connecting member to
moveably couple the cover to the compartment body. An
electroluminescent lamp is molded to the compartment body to
illuminate the cavity. A two-shot molding process may be used to
form the ashtray, with the compartment body and the first
connecting member being formed in the first shot. The
electroluminescent lamp is molded to the compartment body in the
first shot. The cover and the second connecting member are then
formed in the second shot so that the cover is pivotally coupled to
the compartment body.
Inventors: |
Radu; Bogdan; (Dearborn,
MI) ; Dry; Alan G.; (Grosse Point Woods, MI) |
Correspondence
Address: |
WOOD, HERRON & EVANS, LLP (LEAR)
2700 CAREW TOWER
441 VINE STREET
CINCINNATI
OH
45202
US
|
Family ID: |
36084520 |
Appl. No.: |
10/711652 |
Filed: |
September 29, 2004 |
Current U.S.
Class: |
296/37.9 |
Current CPC
Class: |
B60Q 3/225 20170201;
B29C 45/14778 20130101; B60R 2013/0287 20130101; B29L 2031/747
20130101; B29K 2995/0036 20130101; B60R 7/046 20130101; B60R 13/02
20130101; B60Q 3/745 20170201; B29L 2031/3041 20130101; B60Q 3/275
20170201 |
Class at
Publication: |
296/037.9 |
International
Class: |
B60N 3/12 20060101
B60N003/12 |
Claims
1. An automotive interior trim assembly, comprising: a support; and
an ashtray coupled to said support and adapted to store one or more
items, said ashtray comprising: a compartment body defining a
cavity adapted to store the one or more items and having an
interior surface and an opening for gaining access to said cavity;
a cover coupled to said compartment body and moveable between an
open position, wherein said cavity is accessible through said
opening, and a closed position, wherein said cover overlies said
opening; and an electroluminescent lamp coupled to said interior
surface of said cavity and adapted to illuminate said cavity when
said cover is in the open position.
2. The trim assembly of claim 1, wherein said electroluminescent
lamp is molded with the interior surface of said cavity.
3. (canceled)
4. The trim assembly of claim 1 further comprising: an electrical
circuit for energizing said electroluminescent lamp.
5. The trim assembly of claim 4, wherein said electrical circuit
comprises: a power source; a first electrical connector coupled to
said compartment body and electrically coupled to said
electroluminescent lamp; and a second electrical connector coupled
to said support and electrically coupled to said power source,
wherein said first electrical connector is electrically coupled to
said second electrical connector when said ashtray is coupled to
said support so as to energize said electroluminescent lamp.
6. The trim assembly of claim 4, further comprising: an electrical
switch having a first position that energizes the
electroluminescent lamp and a second position that de-energizes the
electroluminescent lamp.
7. The trim assembly of claim 6, wherein said electrical switch is
in the first position when said cover is in the open position and
said electrical switch is in the second position when said cover is
in the closed position.
8. An automotive interior trim assembly, comprising: a support; and
an ashtray coupled to said support and adapted to store one or more
items, said ashtray comprising: a compartment body defining a
cavity adapted to store the one or more items and having an
interior surface and an opening for gaining access to said cavity,
said compartment body including a first connecting member
integrally formed therein; and a cover including a second
connecting member integrally formed therein, said first connecting
member cooperating with said second connecting member to couple
said cover to said compartment body, said cover being moveable
between an open position, wherein said cavity is accessible through
said opening, and a closed position, wherein said cover overlies
said opening; and an electroluminescent lamp coupled to said
interior surface of said cavity and adapted to illuminate said
cavity when said cover is in the open position.
9. (canceled)
10. (canceled)
11. (canceled)
Description
FIELD OF THE INVENTION
[0001] The present invention pertains generally to automotive
interiors and more particularly to ashtrays for automotive
interiors.
BACKGROUND OF THE INVENTION
[0002] It is known to provide automotive interiors with various
trim assemblies to improve the aesthetic appearance of the
automotive interior and for the comfort and convenience of vehicle
occupants. Examples of these interior trim assemblies include the
instrument panels, armrests, door trim panels and consoles. In many
of these trim assemblies, various compartments are incorporated
therein that allow the vehicle occupant to conveniently store one
or more items, such as tissue, coins, cigarette or cigar butts and
ashes, and the like for later removal or disposal thereof. In many
cases, such as for ashtray compartments in door panels or rear
interior side panels, it is desirable for the compartment to
include a door or cover that overlies the opening and secures the
items within the compartment. The cover is typically attached to
the compartment and moveable, such as by a hinge mechanism, so that
the articles in the compartment may be accessed.
[0003] Moreover, in more luxury-oriented vehicles, manufacturers
may provide various lighting systems in the trim assemblies that
enhance the use of the various functional aspects typically found
in the interior of an automobile. For instance, a lighting system
may be provided with the ashtray so that the opening or cavity of
the ashtray may readily be seen during night time conditions or
other conditions when the ashtray may not be readily observed. In
this way, when vehicle occupants need to deposit an item, such as
ashes, in the ashtray, the ashtray opening may be observed and the
ashes deposited therein without turning on overhead lighting, which
may disturb other vehicle occupants. Perhaps more importantly,
however, the lighting system also helps prevent occupants from
missing the ashtray altogether and burning either themselves or the
interior of the vehicle with the hot ashes.
[0004] While being desired by car owners and vehicle occupants,
ashtrays incorporating a lighting system have some drawbacks. A
primary drawback is in the manufacturing and assembly of the
various parts that make up the ashtray and the lighting system. The
current process for making an automotive ashtray is typically to
form the ashtray body in a first mold. The ashtray door is then
individually formed in a second and separate mold. A further
separate connecting member, usually being a pair of metal or
plastic cylindrical hinge pins, is then used to couple the ashtray
door to the ashtray body. Moreover, current ashtrays typically
include a pair of damping mechanisms to provide some resistance to
opening and closing the door to the ashtray.
[0005] To incorporate the lighting system with the ashtray, a
portion of the ashtray body is cut out and covered by a clear
polycarbonate material that in essence, provides a window to the
interior of the ashtray. A separate light assembly is then attached
to the inside of the trim assembly into which the ashtray is
inserted so as to be located adjacent the window in the ashtray
body. In this way, the light assembly emits light through the
window and illuminates the interior of the ashtray. The light
assembly typically includes multiple parts, such as an incandescent
light bulb, a bulb mounting structure, a light cover, light
reflectors and heat stake bosses to manage the heat generated by
the incandescent bulb. The light assembly may further include
contact switches so that the light bulb can be activated when the
door to the ashtray is opened.
[0006] Thus, under current manufacturing processes, ashtrays having
a lighting system provided therewith comprise numerous parts each
having different part numbers that must all be appropriately
supplied, tracked, shipped, inventoried and eventually assembled to
make the complete product. Multiple part assemblies in turn lead to
significant administrative costs and labor costs, which increase
the overall costs of production.
[0007] There is a need for an improved automotive ashtray having a
lighting system and a method for making the same that reduces the
number of parts and reduces the labor required for assembly
thereof, thereby reducing overall manufacturing costs.
SUMMARY OF THE INVENTION
[0008] The present invention provides for an improved automotive
ashtray with a lighting system having a reduced number of parts and
that is adapted to be coupled to an interior trim assembly, such as
a door panel, of a vehicle.
[0009] To this end, the ashtray includes a compartment body
defining a cavity having an opening and adapted to store one or
more items in the cavity such as coins, cigarette and cigar butts
and ashes, and the like. The compartment body has a first
connecting member integrally formed therein. The ashtray further
includes a cover having a second connecting member integrally
formed therein. The first connecting member and the second
connecting member cooperate to pivotally couple the cover to the
compartment body. In this way, the ashtray cover may be opened and
closed to allow access to the cavity. Additionally, an
electroluminescent lamp is coupled to either the compartment body
or the cover and adapted to illuminate the ashtray cavity when the
cover is in the open position.
[0010] The automotive ashtray may be formed by a two shot molding
operation. The electroluminescent lamp is inserted into a mold and
a first mold chamber is formed about the electroluminescent lamp.
In a first shot of the molding operation, a first curable material
is injected into the first mold chamber to form the first element,
i.e. the compartment body or cover, having a first integrated
connecting member. During the first shot, the electroluminescent
lamp is coupled to the first element. Next, a second mold chamber
is formed about at least a portion of the first element, and more
specifically, about a portion of the first connecting member. A
second curable material is then injected into the second mold
chamber in a second shot of the molding operation to form the
second element, i.e. the other of the compartment body or cover,
having a second integrated connecting member. The second element is
formed so that the first connecting member and the second
connecting member are pivotally coupled together. The ashtray
having the electroluminescent lamp incorporated therein may then be
installed into an automotive trim assembly, such as a door
panel.
[0011] By virtue of the foregoing, there is thus provided an
improved automotive ashtray with a lighting system having a reduced
number of parts and that is adapted to be coupled to an interior
trim assembly of a vehicle.
[0012] The features and objectives of the present invention will
become more readily apparent from the following Detailed
Description taken in conjunction with the accompanying
drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] The accompanying drawings, which are incorporated in and
constitute a part of this specification, illustrate embodiments of
the invention and, together with a general description of the
invention given above, and the detailed description given below,
serve to explain the invention.
[0014] FIG. 1 is a side perspective view of an automotive trim
assembly including an embodiment of the ashtray of the present
invention in the form of a door panel;
[0015] FIG. 2 is a perspective view of the ashtray of FIG. 1
showing the electroluminescent lamp;
[0016] FIG. 3 is a detailed partial cross-sectional view of the
electroluminescent lamp shown in FIG. 2; and
[0017] FIGS. 4A-4C are diagrammatic cross-sectional views
illustrating a molding process for forming the ashtray of the
present invention.
DETAILED DESCRIPTION
[0018] In FIG. 1, there is shown an interior trim assembly, in the
form of a door panel 10 for an automobile (not shown), including an
embodiment of the automotive ashtray 12 of the present invention
within a support 14 of door panel 10. The door panel 10 covers a
portion of the interior of the automobile door to provide a more
aesthetically pleasing environment, as well as additional comfort
to the vehicle's occupants. Other various trim assemblies in the
automobile, such as instrument panels, rear passenger side panels
and consoles, are generally constructed in a similar fashion and
may benefit from the present invention. Thus, while the following
detailed description focuses on the ashtray 12 being included in a
door panel 10, those having ordinary skill in the art will
recognize that the ashtray 12 may equally be incorporated in other
automotive trim assemblies.
[0019] The door panel 10 includes a support 14 including a
relatively rigid substrate, which receives the ashtray 12 and which
forms at least a portion of the structural support and defines the
general shape of the door panel 10. The door panel 10 may be
secured to the interior of the automobile, for example, by a
bracket or mounting member (not shown) as is known in the art. The
door panel 10 further includes a front surface 16 that faces the
interior of the automobile and a back surface (not shown) opposite
the front surface 16 that is hidden from view when the panel
assembly 10 is mounted to the automobile.
[0020] As best shown in FIG. 2, the ashtray 12 includes a
compartment body 20 defining a cavity 22 having an opening 24 for
gaining access to the cavity 22. The cavity 22 is adapted to store
one or more items such as coins, cigarette and cigar butts and
ashes, and the like. The compartment body 20 further includes a
pair of spaced apart connecting members 26 integrally formed
therein. While two connecting members 26 are shown in FIG. 2, it
should be understood by those of ordinary skill in the art that one
connecting member or more than two connecting members may be
integrally formed with the compartment body 20. The compartment
body 20 is made of a thermoplastic material such as a thermoplastic
synthetic resin. For example, the compartment body 20 may be formed
from polycarbonate/acrylonitrile butadiene styrene to be heat
resistant to lit cigars and cigarettes as well as hot ashes. The
ashtray 12 also has a cover 30 including one connecting member 32
integrally formed therein. It similarly should be understood by
those having ordinary skill in the art that more than one
connecting member 32 may be integrally formed with the cover 30.
The cover 30 is made of a thermoplastic material such as a
thermoplastic synthetic resin. For example, the cover 30 may be
formed from polypropylene, polyoxymethylene, or polyamide 6.
[0021] As more fully explained in U.S. patent application Ser. No.
10/710,499, which is assigned to assignee of the present invention
and incorporated by reference herein in its entirety, each integral
connecting member 26 of the compartment body 20 includes a
projecting portion defining a pin having an enlarged distal end
configured as a circular portion or ball. The integral connecting
member 32 of the cover 30 includes a pair of spaced apart receiving
portions defining a bore having an enlarged receiving portion
configured as a circular recess. Accordingly, the connecting
members 26 of the compartment body 20 cooperate with the connecting
member 32 of the cover 30 to couple the cover 30 to the compartment
body 20, and more specifically, each circular recess receives one
of the circular portions to pivotally couple the cover 30 to the
compartment body 20. In this way, the cover 30 is moveable between
an open position, wherein the cavity 22 is accessible through the
opening 24, and a closed position, wherein the cover 30 overlies
the opening 24. The ashtray 12 may further include one or more
hinge springs (not shown) cooperating with the compartment body 20
and the cover 30 to assist with movement of the cover 30 from the
open position to the closed position.
[0022] As shown in FIG. 2, to provide lighting to the ashtray 12,
an electroluminescent (EL) lamp, generally shown at 34, may be
coupled to the compartment body 20 and configured to illuminate the
various items placed inside cavity 22. Although the EL lamp 34 is
shown coupled to the compartment body 20, it should be recognized
that the EL lamp 34 may alternately be coupled to cover 30. As
shown in FIG. 3, the EL lamp 34 consists of a stacked structure of
multiple layers carried on a suitable flexible structural substrate
36. The layered structure includes a layer of EL phosphor 38
disposed between substantially parallel front and rear electrodes
40 and 42, respectively. The phosphor layer 38 is contiguous with
the front electrode 40 but spaced from, and electrically isolated
from, the rear electrode 42 by a dielectric layer 44. The front
electrode 40, which faces into the interior of cavity 22, is light
transmissive (i.e., transparent or translucent) for transmitting
light emitted from the phosphor layer 38 when an electric field is
applied between the front and rear electrodes 40, 42. The
dielectric layer 44 may be pigmented to supply a dark or colored
background for the emitted light.
[0023] A protective encapsulation layer 46 of a light-transmissive
substance, such as a polycarbonate or another polymer suitable for
this application, optionally covers the front electrode 40 of the
EL lamp 34. The encapsulation layer 46 may be applied to the
stacked structure as a printed ink layer. An electrical connector
48, shown diagrammatically in FIG. 2, such as an edge electrical
connector, includes power contacts that are coupled with the front
and rear electrodes 40, 42. The power contacts of the electrical
connector 48 are exposed through the encapsulation layer 46 for
establishing electrical contacts.
[0024] The layers of the EL lamp 34 may be printed onto the EL
substrate 36 by rotary screen printing, flexographic printing, or
other printing methods using conducting, insulating and
electroluminescent ink compositions. The ink compositions are
printed across a desired print area on the EL substrate 36 and then
dried to remove volatile solvents for forming stable layers. Some
of the layers in the stacked structure may be printed more than
once in order to assure proper thickness. Phosphor ink compositions
are available to emit light in many colors, such as green, blue,
and yellow, and may also be blended to produce white light
emission. Typical EL phosphors comprise zinc sulfide-based
materials doped to create the desired color emission. Suitable EL
phosphor ink compositions include white, blue-green and
yellow-green LUXPRINT.RTM. electroluminescent inks commercially
available from DuPont Microcircuit Materials (Research Triangle
Park, N.C.)
[0025] In one embodiment of the invention, a flexible metallized
film may effectively function as the EL substrate 36, the rear
electrode 42 and the dielectric layer 44 of the EL lamp 34. Such
metallized films include a thin layer of a metallic conductive
material, like aluminum, deposited on one side of a film material,
like polyester. The deposited metallic layer operates as the rear
electrode 42 and the film material acts as the dielectric layer 44.
The metallized film also serves as a EL substrate 36 for
application of the remaining printed component layers of the
stacked structure.
[0026] Referring again to FIG. 2, the trim assembly further
includes an electrical circuit 50, including an inverter or
converter 51, that electrically couples a power source 52, such as
the vehicle battery, with the electrical connector 48. To this end,
the compartment body 20 includes a first electrical connector 54,
such as a pin connector, that is electrically coupled to the EL
electrical connector 48. For example, the first electrical
connector 54 may be positioned on the underside of the rim of
compartment body 20. Furthermore, the trim assembly may include a
second electrical connector 56, shown diagrammatically in FIG. 2,
electrically coupled to power source 52. For example, second
electrical connector 56 may be positioned in support 14 into which
ashtray 12 is to be inserted. First and second electrical
connectors 54, 56 are configured such that when ashtray 12 is
inserted into door panel 10, the first electrical connector 54
engages, or is otherwise coupled to, electrical connector 56 so as
to energize the EL lamp 34. Electrical circuit 50 may further
include a switch 58 for selectively energizing the EL lamp 34. For
example, power to the EL lamp 34 may be switched in coordination
with the operation of the cover 30 to the ashtray 12 so that the EL
lamp 34 is energized only when the cover 30 is opened. Additional
circuitry, as recognized by persons of ordinary skill in the art,
may be provided as required to ensure proper operation of the EL
lamp 34.
[0027] The converter 51 electrically couples a direct current (DC)
electrical system of the vehicle, such as the vehicle battery, with
the electrical connector 48. The coverter 51 converts the DC
voltage from the electrical system to generate an alternating
current (AC) driving voltage in the range of 80 to 200 VAC,
preferably about 110 VAC, at a frequency in the region of 300 to
500 Hz, preferably about 400 Hz. Application of the AC driving
voltage across the front and rear electrodes 40, 42 of the EL lamp
34 generates a varying electric field within the phosphor layer 38
causing the constituent phosphor particles to emit visible light.
In general, the brightness of the EL lamp 34 increases with
increased voltage and frequency.
[0028] The visible light emitted by the EL lamp 34 uniformly and
effectively illuminates the inside of the cavity 22. The EL lamp 34
has a low power consumption and a very low heat generation as
compared with conventional lamps used in such automotive
applications. Furthermore, the EL lamp 34 is sturdy and exhibits
excellent vibration and impact resistance. The EL lamp 34 will have
a lengthy life and, as a result, will not normally need replacement
over the life of the automobile, in contrast to the need to
periodically replace burnt-out conventional incandescent bulbs. The
EL lamp 34 also has a cooler operating temperature than
conventional incandescent bulbs.
[0029] With reference to FIGS. 4A-4C, a method of making the
ashtray 12 of the present invention will now be described. More
specifically, the ashtray 12 is formed by a two-shot molding
operation wherein a first shot molds one of either the compartment
body 20 or the cover 30. The EL lamp 34 is integrally molded to
either the compartment body 20 or the cover 30 during the first
shot. A second shot then molds the other of the compartment body 20
or cover 30 to couple the parts together.
[0030] To this end, and as shown in FIG. 4A, a first mold 60 is
shown having first and second mold sections 62 and 64,
respectively, that define a first mold chamber or cavity 66 adapted
to mold a first element, i.e., the compartment body 20, in the
first shot. The EL lamp 34 is placed at a specific location between
the first and second mold sections 62, 64 and the mold 60 is
closed. A first curable material 68 is then injected through a
channel 70, into the first cavity 66. The first curable material 68
may be any engineering polymer material suitable for the specific
application, such as polycarbonate/acrylonitrite butadiene styrene.
The injection molding process creates sufficient pressure and heat
to bond the EL lamp 34 and the first curable material 68 to form
the compartment body 20 and EL lamp 34 as an integral structure.
Alternately, first mold 60 may be configured so that first curable
material 68 overmolds a portion of EL lamp 34, such as along its
periphery to couple the EL lamp 34 thereto. Additionally, first
electrical connector 54 may be positioned at a specific location
between first and second mold sections 62, 64 so that first
electrical connector 54 is molded to compartment body 20.
[0031] With reference to FIGS. 4B-4C, after the compartment body 20
is molded having the EL lamp 34 integrally molded thereto, the
compartment body 20 is moved to the second mold 72 having first and
second mold sections 74 and 76, respectively, that define a second
mold chamber or cavity 78 adapted to mold a second element, i.e.,
the cover 30, in the second shot of the molding process. Movement
of the compartment body 20 to the second mold 72 can occur by
methods commonly known in the art such as by hand, i.e. manually,
by robotic means, or by utilizing a rotating mold assembly. With
respect to the rotating mold assembly (not shown), the first
element, e.g. the compartment body, may be formed in a first mold
as stated above. The first mold is then opened and the first
element, rather than being manually or robotically moved, is
rotated, e.g. 180 degrees, on a rotating platen to coordinate with
a second mold to form the second element, e.g. the cover. The
rotating mold assembly advantageously allows for simultaneous
molding of first and second elements.
[0032] After the compartment body 20 has been moved to the second
mold 72, a portion of the connecting members 26 is received within
the second cavity 78 of the second mold 72 so that when the second
mold 72 is closed, second cavity 78 is formed around a portion of
connecting members 26. A second curable material 80 is then
injected through a channel 82 and into second cavity 78. As
explained in more detail in U.S. patent application Ser. No.
10/710,499, this second curable material 80 has a lower melting
point than the first curable material 68. Accordingly, the second
material 80 is provided at a lower temperature than the melting
point of the first material 68 so as to avoid fusion of the
connecting members 26, 32 on the compartment body 20 and cover 30,
respectively. The second material 80 may be a thermoplastic
material such as polypropylene, polyoxymethylene, polyamide 6 or
other suitable materials.
[0033] After the ashtray 12 is formed, the second mold 72 may be
opened and the ashtray 12 ejected therefrom. The two-shot molding
process advantageously provides a unitary ashtray 12 comprising a
compartment body 20, a cover 30 pivotally coupled thereto, and an
EL lamp 34 integrally molded to the compartment body 20 to
illuminate the items stored therein. The unitary ashtray 12 may now
be received within support 14 of the door panel 10 during assembly
of door panel 10. Those having ordinary skill in the art will
recognize that the ashtray 12 may equally be included in other
automotive trim assemblies, e.g. instrument trim lamps, rear
passenger side lamps, center consoles and others.
[0034] Although the above method has described molding the first
element as the compartment body 20 and molding the second element
as the cover 30, it should be understood that the cover 30,
alternatively, could be molded as the first element while the
compartment body 20, alternatively, could be molded as the second
element. Moreover, the EL lamp 34 may be molded to either the
compartment body 20 or cover 30 during the first or second shot of
the molding operation.
[0035] While the present invention has been illustrated by the
description of the various embodiments thereof, and while the
embodiments have been described in considerable detail, it is not
intended to restrict or in any way limit the scope of the appended
claims to such detail. Additional advantages and modifications will
readily appear to those skilled in the art. The invention in its
broader aspects is therefore not limited to the specific details,
representative apparatus and methods and illustrative examples
shown and described. Accordingly, departures may be made from such
details without departing from the scope or spirit of Applicant's
general inventive concept.
* * * * *