Body Produced by an In-Mold Process and Process for the Production Thereof

• US 20150293558A1
• Filed: 10/14/2013
• Published: 10/15/2015
• Est. Priority Date: 10/15/2012
• Status: Active Grant

• Current Assignee: Leohnard Kurz Stiftung & Co. KG, PolyIC GmbH & Co. KG (Leonhard KURZ Stiftung & Company KG)
• Original Assignee: Leonhard KURZ Stiftung & Company KG, PolyIC GmbH & Co. KG (Leonhard KURZ Stiftung & Company KG)
• Inventors: Hahn, Martin, Clemens, Wolfgang, Schindler, Ulrich, Sigritz, Rainer, Golling, Gerald
• Granted Patent: US 9,753,488 B2
• Time in Patent Office: Days
• US Class Current: 1/1
• CPC Class Codes: B29C 2045/14155 using vacuum or suction
• CPC Class Codes: B29C 2045/1477 Removable inserts, e.g. the insert being peeled off after moulding
• CPC Class Codes: B29C 45/14 incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles B29C45/1671 takes precedence
• CPC Class Codes: B29C 45/14016 Intermittently feeding endless articles, e.g. transfer films, to the mould B29C45/14262 takes precedence
• CPC Class Codes: B29C 45/1418 the inserts being deformed or preformed, e.g. by the injection pressure
• CPC Class Codes: B29C 45/14221 by tools, e.g. cutting means
• CPC Class Codes: B29C 45/14262 Clamping or tensioning means for the insert
• CPC Class Codes: B29C 45/14336 Coating a portion of the article, e.g. the edge of the article B29C45/14573 and B29C45/14598 take precedence
• CPC Class Codes: B29C 45/14377 using an additional insert, e.g. a fastening element
• CPC Class Codes: B29C 45/14639 for obtaining an insulating effect, e.g. for electrical components
• CPC Class Codes: B29C 45/14754 being in movable or releasable engagement with the coating, e.g. bearing assemblies
• CPC Class Codes: B29C 45/14778 the article consisting of a material with particular properties, e.g. porous, brittle
• CPC Class Codes: B29C 45/44 for undercut articles
• CPC Class Codes: G06F 1/16 Constructional details or arrangements
• CPC Class Codes: G06F 2203/04103 Manufacturing, i.e. details related to manufacturing processes specially suited for touch sensitive devices
• CPC Class Codes: G06F 2203/04107 Shielding in digitiser, i.e. guard or shielding arrangements, mostly for capacitive touchscreens, e.g. driven shields, driven grounds
• CPC Class Codes: G06F 3/0443 using a single layer of sensing electrodes
• CPC Class Codes: G06F 3/045 using resistive elements, e.g. a single continuous surface or two parallel surfaces put in contact
• CPC Class Codes: H05K 1/028 Bending or folding regions of flexible printed circuits H05K1/0283 takes precedence
• CPC Class Codes: H05K 1/092 Dispersed materials, e.g. conductive pastes or inks
• CPC Class Codes: H05K 2201/0145 : Polyester, e.g. polyethylene terephthalate [PET], polyethylene naphthalate [PEN]
• CPC Class Codes: H05K 2201/026 : Nanotubes or nanowires
• CPC Class Codes: H05K 3/0014 : Shaping of the substrate, e.g. by moulding

Abstract

A body (1, 1′, 1″) produced by an in-mold process has a first film (2, 2′, 2″) with at least one electrical or electronic functional layer (25). In a functional area (20a, 20a′, 20a″) of this functional layer, at least one electrical or electronic component is provided, and at least one electrical connection for this is provided in a contact area (20b, 20b′, 20b″). The first film is partially back-injection molded with a plastic main material (3, 3′, 3″) such that the contact area (20b, 20b′, 20b″) is at least partially free from this plastic main material (3). Suitable formation of the first film (2, 2′, 2″) guarantees that a tab (F) separated from the plastic main material (3, 3′, 3″) is provided which adjoins a back-injection molded part of the first film in an area of surface (20c, 20c′, 20c″) of the body which is at a distance from an edge (31, 31′) of the body delimiting the surface (30) with the first film.

Claims

1. A body which has a first film with at least one electrical and/or electronic functional layer, wherein at least one electrical and/or electronic component is provided in a functional area of the functional layer, and wherein at least one electrical connection is provided in a contact area of the at least one functional layer, which electrical connection is galvanically coupled to at least one component, wherein the body furthermore comprises a plastic main material with which the first film is partially back-injection molded such that the contact area is at least partially free from plastic main material, wherein the first film is formed such that a tab separated from the plastic main material is provided by a non back injection-molded part of the first film, which tab adjoins a back-injection molded part of the first film in an area of surface of the body which is at a distance from an edge of the body delimiting the surface with the first film.

2. A body according to claim 1, wherein the plastic main material predefines a shape of the body which makes it possible at least partially to bring the tab up against the surface of the plastic main material on its side with the first film.

3. A body according to claim 1, wherein the body has a flat surface, on which the first film is arranged, and wherein the tab can be brought into a position or is located in a position in which it protrudes at an angle from the range of from 15°

to 90°

to the plane from an area of surface which is adjoined on all sides in respect of the surface by plastic main material.

4. A body according to claim 1, wherein the body has a curved surface, on which the first film is arranged, and wherein the tab can be brought into a position or is located in a position in which it protrudes at an angle from the range of from 75°

to 0°

to a surface normal of the curved surface at an area of surface which is adjoined on all sides in respect of the surface by plastic main material.

5. A body according to claim 1, wherein a transition from a back-injection molded part of the first film to a non back-injection molded part of the film takes place along a line on the surface which is at a distance of at least 8 mm, from an edge contour of the body delimiting the surface with the first film.

6. A body according to claim 1, further comprising a second film or a lacquer package which is likewise back-injection molded with the plastic main material and has a decoration layer which is over the whole surface or partial and which provides at least one item of information in respect of the at least one electrical and/or electronic component.

7. A body according to claim 1, wherein the functional layer comprises capacitive components which provide a touch panel functionality.

8. A body according to claim 1, further comprising a stiffening element with a thickness from the range of from 140 to 580 μ

m, and/or an additional contact element with a thickness from the range of from 1 to 15 μ

m, on the tab.

9. A body according to claim 1, wherein the plastic main material is a thermoplastic which comprises polymethyl acrylate, acrylonitrile-butadiene-styrene, polycarbonate and/or polyamide.

10. A body according to claim 1, wherein the plastic main material is transparent at least in areas.

11. A body according to claim 1, wherein the functional layer has a plurality of conductor traces which consist of silver, copper, aluminum, chromium or of a metal alloy, and which have a width of between 1 μ

m and 40 μ

m and have a distance from each other of between 10 μ

m and 5 mm and are preferably provided in a layer thickness of from 30 to 60 nm.

12. A body according to claim 1, wherein the functional layer has a plurality of conductor traces which consist of silver, copper, aluminum, chromium or of a metal alloy, and which have a width of 100 μ

m or more.

13. A body according to claim 1, wherein the functional layer comprises metal nanowires, made of silver, copper, gold, metal nanoparticles, made of silver, copper or gold, carbon nanotubes, carbon nanoparticles, graphene, and/or organic conductors and/or polyaniline and/or provides organic light-emitting diodes, inorganic or organic photovoltaic cells, display elements provided using electroluminescent materials, electrochromic materials and/or electrophoretic materials, integrated circuits and/or inorganic or organic memories.

14. A body according to claim 1, further comprising with a substrate carrying the functional layer and made of polyethylene terephthalate, polypropylene, polycarbonate, polyethylene naphthalate, which is provided in a thickness of between 35 and 60 μ

m.

15. A body according to claim 14, wherein the substrate is arranged between the functional layer and the plastic main material.

16. A body according to claim 14, wherein the functional layer is arranged between the substrate and the plastic main material.

17. A body according to claim 1, further comprising an adhesion-promoter layer at least on the part of the first film back-injection molded with plastic.

18. A body according to claim 17, wherein the adhesion-promoter layer consists of two partial layers which are formed from different material.

19. An electrical device, with a housing, in or against which a body according to claim 1 is placed, wherein an electrical or electronic component is arranged in the housing, which component is galvanically coupled, via the tab protruding from the plastic main material, to the electrical or electronic functional layer.

20. A process for producing a body according to claim 1 wherein a first film is inserted into an injection mold, wherein the first film, in a first area, has adhesion properties in respect of a predetermined injection-molding material which are qualitatively better than the corresponding adhesion properties in a second area of the first film, wherein the second area has the form of a tongue protruding from the first area, wherein in the process the predetermined injection-molding material is injected into the injection mold with the first film, with the result that the first film is partially back-injection molded and then the produced body is removed, in which, because of the different adhesion properties, injection-molding material adheres to the first film in the first area, but injection-molding material adheres poorly or does not adhere to the first film in the second area.

21. A process according to claim 20, wherein a film is inserted which comprises an adhesion-promoter layer in the first area.

22. A process according to claim 20, wherein a film is inserted which comprises, in the second area, a layer suppressing the adhesion.

23. A process for producing a body according to claim 1, wherein a first film is inserted into an injection mold, which film has a first area from which a second area protrudes in the form of a tongue, and wherein in the process the second area is clamped between two clamping parts and wherein injection-molding material is injected into the injection mold and thus the first area of the first film is back-injection molded.

24. A process according to claim 23, wherein the injection mold is formed such that injection-molding material is provided on both sides of a transition area from the first area to the second area of the first film.

25. A process according to claim 23, wherein the clamping elements comprise a mold half of the injection mold and either a separate slide, an inclined ejector guided in the mold half of the injection mold or a spring-loaded ejector mounted in the mold half of the injection mold.

26. A process according to claim 23, wherein the clamping elements comprise two clamping jaws that can be separated from each other by a collapsible core.

27. A process according to claim 23, wherein a first film is inserted into an injection mold, wherein the first film, in a first area, has adhesion properties in respect of a predetermined injection-molding material which are qualitatively better than the corresponding adhesion properties in a second area of the first film, wherein the second area has the form of a tongue protruding from the first area, wherein in the process the predetermined injection-molding material is injected into the injection mold with the first film, with the result that the first film is partially back-injection molded and then the produced body is removed, in which, because of the different adhesion properties, injection-molding material adheres to the first film in the first area, but injection-molding material adheres poorly or does not adhere to the first film in the second area.

28. A process according to claim 20, wherein a second film is introduced into the injection mold, which film is likewise back-injection molded.

29. A process according to claim 28, wherein, as second film, a film is inserted which comprises a carrier layer and a transfer layer and is supplied in a roll-to-roll process, wherein, after the back-injection molding, the transfer layer at least partially adheres to the injection-molding material and is detached from the carrier layer, and wherein the carrier layer is taken away in the roll-to-roll process.

30. A film element for use as part of a body according to claim 1, which has a substrate, and an electrical or electronic functional layer, wherein the film element has, on one surface side, a first area and a second area which differ from each other by their different adhesiveness in respect of a predetermined injection-molding material.

31. A film element according to claim 30, wherein the first area is provided with an adhesion-promoter layer and the second area is not.

32. A film element according to claim 30, wherein an adhesion-promoter layer is applied over the whole surface in the first and in the second area, wherein in the second area on the adhesion-promoter layer a layer suppressing the adhesion is provided.