Method of making illuminated covers

• US 6,773,644 B1
• Filed: 01/07/2002
• Issued: 08/10/2004
• Est. Priority Date: 08/29/2001
• Status: Expired due to Fees

• Current Assignee: 2011 Intellectual Property Asset Trust (Nokia Corporation)
• Original Assignee: Nokia Corporation
• Inventors: Eiden, Niko
• Primary Examiner(s): ORTIZ, ANGELA Y
• Application Number:
  US10/036,478
• Time in Patent Office: 946 Days
• Field of Search: 264/129, 264/132, 264/134, 264/135, 264/138, 264/139, 264/154, 264/155, 264/156, 264/161, 264/163, 264/250, 264/254, 264/255, 264/259, 264/263, 264/265, 264/266, 264/271.1, 264/275, 264/278, 156/196, 156/219, 156/220, 156/245
• US Class Current: 264/132
• CPC Class Codes: B29C 2045/14237 the inserts being deformed or preformed outside the mould or mould cavity
• CPC Class Codes: B29C 2045/14844 Layers protecting the insert from injected material
• CPC Class Codes: B29C 45/14811 Multilayered articles B29C45/14827 takes precedence
• CPC Class Codes: B29C 45/2628 with mould parts forming holes in or through the moulded article, e.g. for bearing cages
• CPC Class Codes: B29K 2995/002 Coloured
• CPC Class Codes: B29K 2995/0036 Electroluminescent
• CPC Class Codes: B29K 2995/0087 Wear resistance
• CPC Class Codes: B29L 2031/3437 Cellular phones
• CPC Class Codes: H04M 1/0283 for providing a decorative aspect, e.g. customization of casings, exchangeable faceplate
• CPC Class Codes: H04M 1/22 Illumination; Arrangements for improving the visibility of characters on dials

Abstract

As illuminated cover, a method of making such a cover, and a covered electronic device. An electroluminescent foil overlies a thin, rigid support base, and an insulating foil overlies the electroluminescent foil. A first opening allows insertion of an electrical connector for the electroluminescent foil. A second opening allows insertion of a control key of an electronic device covered by the decorative cover. The covered electronic device further includes a printed circuit board having electronic components mounted on it, including the control key. A connector extends into the first opening to connect the electroluminescent foil to circuitry on the printed circuit board so as to provide electrical power to the electroluminescent foil. A second base cooperates with the support base to enclose the electronic device. A graphic can be included between the electroluminescent foil and the insulating foil. The cover is made by a molding method.

Claims

1. A method of forming a device cover having a predetermined shape, said method comprising:

forming a preliminary cover member by attaching a first surface of an electroluminescent foil to a first surface of an electrically insulating foil, the electrically insulating foil having the predetermined shape and having at least one first opening and at least one second opening therethrough, the electroluminescent foil having at least one opening therethrough corresponding with the at least one first opening through the electrically insulating foil and the at least one second opening exposes a surface of the electroluminescent foil;

placing the preliminary cover member in a mold of the predetermined shape, the mold having bosses corresponding with the at least one first opening and with the at least one second opening; and

injecting plastic into the mold and into contact with the preliminary cover member to form the device cover, the bosses providing opening is through the plastic corresponding with the at least one first opening and the at least one second opening so that when the mold is opened the at least one first opening extends through the device cover and the at least one second opening extends to the surface of the electroluminescent foil.

2. A method as claimed in claim 1, further comprising, before forming the preliminary cover member, preforming the electrically insulating foil to the predetermined shape and forming the at least one first opening through the electrically insulating foil.

3. A method as claimed in claim 2, wherein the preforming includes forming a ridge around the at least one first opening through the electrically insulating foil, and wherein the at least one first opening through the electroluminescent foil surrounds the ridge to position the electroluminescent foil on the electrically insulating foil.

4. A method as claimed in claim 1, further comprising, before forming the preliminary cover member, forming the at least one first opening through the electroluminescent foil.

5. A method as claimed in claim 1, wherein forming the preliminary cover member includes attaching the first surface of the electroluminescent foil to a first surface of an electrically insulating foil having a graphic thereon.

6. A method as claimed in claim 4, wherein forming the preliminary cover member includes attaching a thermally insulating foil to a second surface of the electroluminescent foil, the thermally insulating foil having openings therethrough corresponding with the at least one first opening and the at least one second opening.

7. A method as claimed in claim 1, further comprising, before forming the preliminary cover member, providing a graphic on the first surface of the electrically insulating foil.

8. A method as claimed in claim 7, wherein forming the preliminary cover member includes attaching a thermally insulating foil to a second surface of the electroluminescent foil, the thermally insulating foil having openings therethrough corresponding with the at least one first opening and the at least one second opening.

9. A method as claimed in claim 1, further comprising, before forming the preliminary cover member, providing a graphic on the electroluminescent foil.

10. A method as claimed in claim 9, wherein forming the preliminary cover member includes attaching a thermally insulating foil to a second surface of the electroluminescent foil, the thermally insulating foil having openings therethrough corresponding with the at least one first opening and the at least one second opening.

11. A method as claimed in claim 1, wherein forming the preliminary cover member includes positioning a further foil between the electrically insulating foil and the electroluminescent foil, the further foil having a graphic on a surface thereof, the further foil attaching the electroluminescent foil to the electrically insulating foil.

12. A method as claimed in claim 11, wherein forming the preliminary cover member includes attaching a thermally insulating foil to a second surface of the electroluminescent foil, the thermally insulating foil having openings therethrough corresponding with the at least one first opening and the at least one second opening.

13. A method as claimed in claim 1, further comprising:

allowing the plastic to cool; and

removing the decorative cover from the mold.

14. A method of forming a device cover having a predetermined shape, said method comprising:

forming a preliminary cover member by attaching a first surface of an electroluminescent foil to a first surface of an electrically insulating foil, the electrically insulating foil having the predetermined shape, the electroluminescent foil having at least one first opening therethrough;

forming at least one first opening through the electrically insulating foil at a location corresponding with the at least one first opening through the electroluminescent foil and at least one second opening therethrough;

placing the preliminary cover member in a mold of the predetermined shape, the mold having bosses corresponding with the at least one first opening and with the at least one second opening; and

injecting plastic into the mold and into contact with the preliminary cover member to form the device cover, the bosses providing opening through the plastic corresponding with the at least one first opening and the at least one second opening so that when the mold is opened, the at least one first opening extends through the device cover and the at least one second opening extends to the surface of the electroluminescent foil.

15. A method as claimed in claim 14, further comprising, before forming the preliminary cover member, preforming the electrically insulating foil to the predetermined shape.

16. A method as claimed in claim 14, further comprising, before forming the preliminary cover member, forming the at least one first opening and the at least one second opening through the electroluminescent foil.

17. A method as claimed in claim 14, wherein forming the preliminary cover member includes attaching the first surface of the electroluminescent foil to a first surface of an electrically insulating foil having a graphic thereon.

18. A method as claimed in claim 17, wherein forming the preliminary cover member includes attaching a thermally insulating foil to a second surface of the electroluminescent foil, the thermally insulating foil having at least one first opening and at least one second opening therethrough corresponding with the at least one first opening and the at least one second opening.

19. A method as claimed in claim 14, further comprising, before forming the preliminary cover member, providing a graphic on the first surface of the electrically insulating foil.

20. A method as claimed in claim 19, wherein forming the preliminary cover member includes attaching a thermally insulating foil to a second surface of the electroluminescent foil, the thermally insulating foil having at least one first opening and at least one second opening therethrough corresponding with the at least one first opening and the at least one second opening.

21. A method as claimed in claim 14, further comprising, before forming the preliminary cover member, providing a graphic on the electroluminescent foil.

22. A method as claimed in claim 21, wherein forming the preliminary cover member includes attaching a thermally insulating foil to a second surface of the electroluminescent foil, the thermally insulating foil having at least one first opening and at least one second opening therethrough corresponding with the at least one first opening and the at least one second opening.

23. A method as claimed in claim 14, wherein forming the preliminary cover member includes positioning a further foil between the electrically insulating foil and the electroluminescent foil, the further foil having a graphic on a surface thereof.

24. A method as claimed in claim 23, wherein forming the preliminary cover member includes attaching a thermally insulating foil to a second surface of the electroluminescent foil, the thermally insulating foil having at least one first opening and at least one second opening therethrough corresponding with the at least one first opening and the at least one second opening.

25. A method as claimed in claim 14, further comprising:

allowing the plastic to cool; and

removing the decorative cover from the mold.