Multifunctional laminate structure and process

• US 6,399,903 B1
• Filed: 02/15/2000
• Issued: 06/04/2002
• Est. Priority Date: 03/01/1999
• Status: Expired due to Fees

• Current Assignee: Honeywell International Inc.
• Original Assignee: Honeywell International Inc.
• Inventors: Stevenson, James F.
• Primary Examiner(s): SCOTT, JAMES R
• Application Number:
  US09/500,957
• Time in Patent Office: 840 Days
• Field of Search: 200/5.R, 200/5.A, 200/512-517, 200/304, 200/305, 200/86.R, 200/308-316, 361/212-220, 174/35.MS, 174/250-268, 455/500, 455/575, 455/90
• US Class Current: 200/5.00A
• CPC Class Codes: G06F 1/182 with special features, e.g. for use in industrial environments; grounding or shielding against radio frequency interference [RFI] or electromagnetical interference [EMI]
• CPC Class Codes: H01Q 1/242 specially adapted for hand-held use
• CPC Class Codes: H01Q 1/42 Housings not intimately mechanically associated with radiating elements, e.g. radome
• CPC Class Codes: H04B 15/00 Suppression or limitation of noise or interference by means associated with receiver H04B1/10
• CPC Class Codes: H05K 1/0218 by printed shielding conductors, ground planes or power plane H05K1/0236 takes precedence
• CPC Class Codes: H05K 1/0393 Flexible materials H05K1/038 takes precedence; specific organic compositions are classified in H05K1/0313 and subgroups
• CPC Class Codes: H05K 2201/0195 Dielectric or adhesive layers comprising a plurality of layers, e.g. in a multilayer structure
• CPC Class Codes: H05K 2201/09936 Marks, inscriptions, etc. for information
• CPC Class Codes: H05K 3/0064 onto a polymeric substrate
• CPC Class Codes: H05K 9/0084 comprising a single continuous metallic layer on an electrically insulating supporting structure, e.g. metal foil, film, plating coating, electro-deposition, vapour-deposition

Abstract

A multilayered structural element which is useful for forming housings for electronic devices such as cellular telephones. The multilayered structural element has sequentially attached layers:

(a) thin, flexible polymeric outer film layer,

(b) an electronic interface layer, the electronic interface layer comprising a thin, flexible polymeric film layer having a pattern of electrically conductive lines on at least one side thereof;

(c) a rigid structural layer;

(d) an electromagnetic interference shielding layer; and

(e) an optional protective layer.

Claims

1. A multilayered structural element for attachment to electronic circuitry which comprises as sequentially attached layers:

(a) thin, flexible polymeric outer film layer,

(b) an electronic interface layer, the electronic interface layer comprising a thin, flexible polymeric film layer having a pattern of electrically conductive lines on at least one side thereof;

(c) a rigid structural layer;

(d) an electromagnetic interference shielding layer; and

(e) an optional protective layer.

2. The structural element of claim 1 wherein the protective layer is present.

3. The structural element of claim 1 wherein the outer film layer comprises a material selected from the group consisting of nylons, polycarbonates, thermoplastic elastomers, thermoplastic polyesters, polyolefins, polyurethanes, polyvinyl chloride, acrylonitrile-butadiene-styrene polymers, polyoxyalkylenes, polystyrene, liquid crystal polymers, and copolymers and blends thereof.

4. The structural element of claim 1 wherein an outer surface of the outer film layer has one or more sections which are continuous, discontinuous, embossed, raised or perforated.

5. The structural element of claim 1 wherein the outer film layer comprises a keypad having a plurality of indicia visible at an outer surface thereof and a plurality of electrically conductive contacts at an inner surface thereof which correspond to the indicia.

6. The structural element of claim 1 wherein the outer film layer comprises a visible display comprising at least one display element capable of being activated electronically or thermally.

7. The structural element of claim 1 wherein the outer film layer comprises a visible display comprising at least one display element capable of being activated electronically or thermally and which comprises a light emitting diode, a liquid crystal display element or an optical fiber.

8. The structural element of claim 1 wherein the electronic interface layer comprises one or more circuits selected from the group consisting of circuitry for a keypad, circuitry for an antenna, circuitry for issuing a tactile signal, circuitry for issuing a visible signal, and circuitry for issuing an audible signal.

9. The structural element of claim 1 wherein the rigid structural layer comprises a fiber reinforced polymer composition.

10. The structural element of claim 1 wherein the rigid structural layer comprises a woven or nonwoven web comprising glass fibers, carbon fibers, thermoplastic fibers, or combinations thereof.

11. The structural element of claim 1 wherein the rigid structural layer comprises glass or carbon fibers impregnated with a polymeric material.

12. The structural element of claim 1 wherein the rigid structural layer comprises glass or carbon fibers impregnated with a polymeric material selected from the group consisting of nylons, polycarbonates, thermoplastic elastomers, thermoplastic polyesters, polyolefins, polyurethanes, polyvinyl chloride, acrylonitrile-butadiene-styrene polymers, polyoxyalkylenes, polystyrene, liquid crystal polymers, and copolymers and blends thereof.

13. The structural element of claim 1 wherein the rigid structural layer has a flexural modulus of from about 3,000 MPa to about 100,000 MPa.

14. The structural element of claim 1 wherein the electromagnetic interference shielding layer comprises a metal foil or a metalized polymer film.

15. The structural element of claim 1 wherein the protective layer comprises a foamed polymer.

16. An electronic device which comprises an electronic circuit element and the structural element of claim 1 attached on a side of the circuit element, such that the circuit element is attached to the electromagnetic interference shielding layer or the protective layer;

and the conductive lines of the electronic interface layer form an electric connection with the circuit element.

17. The electronic device of claim 16 further comprising a molding attached around an outer peripheral edge of the circuit element and the structural elements.

18. The electronic device of claim 16 which is a telephone and the circuit element comprises a telephone circuit element.

19. The electronic device of claim 16 which is a display panel.

20. An electronic device which comprises as sequentially attached elements:

i) a first multilayered structural element which comprises as sequentially attached layers;

(a) a thin, flexible polymeric outer film layer,

(b) an electronic interface layer, the electronic interface layer comprising a thin, flexible polymeric film layer having a pattern of electrically conductive lines on at least one side thereof;

(c) a rigid structural layer;

(d) an electromagnetic interference shielding layer; and

(e) an optional protective layer;

ii) an electronic circuit element attached to the electromagnetic interference shielding layer or the protective layer of the first multilayered structural element wherein the conductive lines of the electronic interface layer forms an electric connection with the circuit element; and

iii) a second multilayered structural element, which comprises as sequentially attached layers;

(a) a thin, flexible polymeric outer film layer,

(b) an optional electronic interface layer, the electronic interface layer comprising a thin, flexible polymeric layer having a pattern of electrically conductive lines on at least one side thereof;

(c) a rigid structural layer;

(d) an electromagnetic interference shielding layer; and

(e) an optional protective layer;

the circuit element being attached to the electromagnetic interference shielding layer or the protective layer of the second multilayered structural element.

21. The electronic device of claim 20 which is a telephone and the circuit element comprises a telephone circuit element.

22. The electronic device of claim 20 which is a display panel.

23. A telephone which comprises a first telephone half hingedly and electrically connected to a second telephone half, each telephone half comprising as sequentially attached elements:

i) a first multilayered structural element, which comprises as sequentially attached layers;

(a) a thin, flexible polymeric outer film layer,

(b) an electronic interface layer, the electronic interface layer comprising a thin, flexible polymeric film layer having a pattern of electrically conductive lines on at least one side thereof;

(c) a rigid structural layer;

(d) an electromagnetic interference shielding layer; and

(e) an optional protective layer attached;

ii) an electronic telephone circuit element attached to the electromagnetic interference shielding layer or the protective layer of the first multilayered structural element, wherein the conductive lines of the electronic interface layer forms an electric connection with the telephone circuit element; and

iii) a second multilayered structural element, which comprises as sequentially attached layers;

(a) a thin, flexible polymeric outer film layer,

(b) an optional electronic interface layer, the electronic interface layer comprising a thin, flexible polymeric film layer having a pattern of electrically conductive lines on at least one side thereof;

(c) a rigid structural layer;

(d) an electromagnetic interference shielding layer; and

(e) an optional protective layer;

the telephone circuit element being attached to the electromagnetic interference shielding layer or the protective layer of the second multilayered structural element.