Multi-shot molded touch switch

• US 6,960,735 B2
• Filed: 03/17/2004
• Issued: 11/01/2005
• Est. Priority Date: 03/17/2004
• Status: Expired due to Fees

• Current Assignee: Lear Corporation
• Original Assignee: Lear Corporation
• Inventors: Cass, Michael W., Hein, David A., DePue, Todd L., Banter, Charles B.
• Primary Examiner(s): Scott, James R.
• Application Number:
  US10/802,193
• Publication Number:
  US 20050205407A1
• Time in Patent Office: 594 Days
• Field of Search: 200/5.A, 200512-517, 200/600, 341/27, 341/33, 345/173
• US Class Current: 200/600
• CPC Class Codes: B29C 2045/169 injecting electrical circuits, e.g. one layer being made of conductive material
• CPC Class Codes: B29C 45/16 Making multilayered or multicoloured articles B29C45/0062 takes precedence; feeding colouring materials into the injection unit B29C45/1816
• CPC Class Codes: B29C 45/1671 with an insert
• CPC Class Codes: B29L 2031/3443 Switches
• CPC Class Codes: B29L 2031/3493 Moulded interconnect devices, i.e. moulded articles provided with integrated circuit traces
• CPC Class Codes: H01H 13/88 Processes specially adapted for manufacture of rectilinearly movable switches having a plurality of operating members associated with different sets of contacts, e.g. keyboards
• CPC Class Codes: H01H 2207/002 Conductive rubber; Zebra
• CPC Class Codes: H01H 2229/046 Multi-colour or double shot injection moulding
• CPC Class Codes: H01H 2231/026 Car
• CPC Class Codes: H01H 2239/006 Containing a capacitive switch or usable as such
• CPC Class Codes: H05K 1/095 for polymer thick films, i.e. having a permanent organic polymeric binder
• CPC Class Codes: H05K 3/107 by filling grooves in the support with conductive material H05K3/045, H05K3/101, H05K3/1258 and H05K3/465 take precedence
• CPC Class Codes: H05K 3/1258 by using a substrate provided with a shape pattern, e.g. grooves, banks, resist pattern

Abstract

A conductive plastic touch switch includes a plastic substrate having a first side surface including at least two channels formed within the first side surface and a second side surface including a manual activation region opposite of the at least two channels. At least two conductive traces are formed within the at least two channels, respectively. A printed circuit board is electrically attached to the at least two conductive traces. The plastic substrate is formed during a first mold process and said at least two conductive traces are in-molded during a second mold process.

Claims

1. A conductive plastic touch switch, the touch switch comprising:

a plastic substrate having a first side surface including at least two channels formed within said first side surface and a second side surface including a manual activation region opposite of said at least two channels;

at least two conductive traces formed within said at least two channels respectively; and

a printed circuit board electrically attached to said at least two conductive plastic traces;

wherein said plastic substrate is formed during a first mold process and said at least two conductive plastic traces are in-molded during a second mold process.

2. The touch switch of claim 1 wherein said at least two conductive traces are plastic conductive traces formed during said second mold process.

3. The touch switch of claim 2 wherein said at least two conductive plastic traces are arranged in a pattern at a predetermined distance apart, said at least two conductive plastic traces generating an electric field with said manual activation region when a predetermined voltage is applied to said at least two conductive traces.

4. The touch switch of claim 3 wherein capacitances generated by said two conductive plastic traces varies in response to an object selectably disposed within said manual activation region.

5. The touch switch of claim 4 wherein at least two conductive plastic traces are plated with a conductive modifier for increasing said conductivity of said at least two conductive plastic traces.

6. The touch switch of claim 5 wherein said conductive modifier is plated on said two conductive plastic traces in an electroplating process.

7. The touch switch of claim 1 further comprising a zebra connector for electrically connecting said printed circuit board to said at least two conductive traces.

8. The touch switch of claim 1 further comprising a third channel formed within said first side surface, wherein a ground trace is molded within said third channel.

9. The touch switch of claim 1 wherein said interior trim panel comprises an instrument panel.

10. The touch switch of claim 1 wherein said interior trim panel comprises a bezel.

11. The touch switch of claim 1 wherein said at least two conductive traces are insert molded during said second mold process.

12. The touch switch of claim 1 wherein said at least two conductive traces are formed on different planes.

13. A conductive plastic touch switch formed in an interior trim panel of a vehicle, the touch switch comprising:

a plastic substrate forming a portion of an interior trim panel of a vehicle, a first side surface including at least two channels formed within said first side surface and a second side surface including a manual activation region opposite said at least two channels;

at least two conductive plastic traces, said conductive plastic traces formed within said at least two channels; and

a printed circuit board electrically attached to said at least two conductive traces;

wherein said plastic substrate is formed during a first mold process and said at least two conductive plastic traces are in-molded during a second mold process.