Integrated electromechanical arrangement and method of production

• US 7,200,009 B2
• Filed: 07/01/2003
• Issued: 04/03/2007
• Est. Priority Date: 07/01/2003
• Status: Active Grant

• Current Assignee: Nokia Technologies Oy (Nokia Corporation)
• Original Assignee: Nokia Corporation
• Inventors: Tanskanen, Pia, Ahlgren, Pentti, Takala, Roope, Nousiainen, Jari, Narhi, Katri
• Primary Examiner(s): Reichard; Dean A.
• Assistant Examiner(s): CARPIO, IVAN HERNAN
• Application Number:
  US10/612,397
• Publication Number:
  US 20050002168A1
• Time in Patent Office: 1,372 Days
• Field of Search: 361/800, 361/749, 361/760, 361/759, 174/260
• US Class Current: 361/759
• CPC Class Codes: B29C 45/14639 for obtaining an insulating effect, e.g. for electrical components
• CPC Class Codes: B29C 45/14688 Coating articles provided with a decoration
• CPC Class Codes: G06F 3/0202 Constructional details or processes of manufacture of the input device
• CPC Class Codes: G06F 3/03547 Touch pads, in which fingers can move on a surface
• CPC Class Codes: H01H 13/81 characterised by electrical connections to external devices
• CPC Class Codes: H01H 13/86 characterised by the casing, e.g. sealed casings or casings reducible in size
• CPC Class Codes: H01H 2207/008 Adhesive means; Conductive adhesive
• CPC Class Codes: H01H 2207/02 Solder
• CPC Class Codes: H01H 2215/008 Part of substrate or membrane
• CPC Class Codes: H01H 2219/002 replaceable; adaptable
• CPC Class Codes: H01H 2219/018 Electroluminescent panel
• CPC Class Codes: H01H 2219/028 Printed information
• CPC Class Codes: H01H 2223/028 detachable
• CPC Class Codes: H01H 2229/047 Preformed layer in mould
• CPC Class Codes: H01H 2229/05 Forming; Half-punching
• CPC Class Codes: H05K 1/189 characterised by the use of a flexible or folded printed circuit H05K3/326 takes precedence
• CPC Class Codes: H05K 2203/1327 Moulding over PCB locally or completely applying non-metallic protective coatings for encapsulating mounted components H05K3/284
• CPC Class Codes: H05K 3/0058 Laminating printed circuit boards onto other substrates, e.g. metallic substrates H05K1/0281 takes precedence
• CPC Class Codes: H05K 3/4015 using auxiliary conductive elements, e.g. pieces of metal foil, metallic spheres

Abstract

It is an object of the invention to provide a electromechanical structure comprising an input device and a printed wired board (3, 4), which structure is advantageous in terms of manufacturing and offers freedom to the layout design of the printed wired board, the user interface as well as the appearance of the device itself. It is also an object of the invention to provide a electromechanical structure that is compact and facilitates the customizability and upgradability with a new electronic functionality without any need for modifications to the main electronics of the device. This is achieved by integrating the electromechanical assembly with the mechanical cover part of the electronic device by using an injection moulding process to compose an integrated combination (113) which is detachable from the electronic device. More precisely the objects of the invention are achieved by combining the injection mould technologies with the printing of electronic wired boards.

Claims

1. An electromechanical assembly for an electronic device, the electromechanical assembly comprising at least a printed wired foil and means for electrically connecting the electromechanical assembly to the electronic device, the electronic device comprising at least one cover part and means for mechanically connecting the cover part to the electronic device, wherein the electromechanical assembly is arranged to be an insert during an injection molding process to produce the cover part so that the electromechanical assembly and the cover part are arranged to compose an integrated combination which is detachable from the electronic device.

2. An electromechanical assembly according to claim 1, wherein the electromechanical assembly is integrated into the cover part to compose an integrated combination which is detachable from the electronic device.

3. An electromechanical assembly according to claim 1, wherein the printed wired foil is separated from the engine printed wired board of the electronic device.

4. An electromechanical assembly according to claim 1, wherein the printed wired foil comprises:

wiring to provide electrical connections to contact points and between the contact points for components of the electromechanical assembly and to contact points electrically connecting by connecting means the electromechanical assembly to the electronic device,

isolation layers,

decorations, and

electronic and mechanical components mounted on the appropriate contact points onto the printed wired foil.

5. An electromechanical assembly according to claim 1, wherein the connecting means, preferably small cylindrical connectors are soldered or glued to the contact points electrically connecting the electromechanical assembly to the electronic device.

6. An electromechanical assembly according to claim 5, wherein the electromechanical assembly is an input device assembly comprising at least an input device connected to a printed wired foil and means for electrically connecting the input device assembly to the electronic device, wherein the input device assembly is integrated into the cover part to compose an integrated combination which is detachable from the electronic device.

7. An electromechanical assembly according to claim 1, wherein the electromechanical assembly is a keypad assembly comprising at least a keypad connected to a printed wired foil and means for electrically connecting the keypad assembly to the electronic device, wherein the keypad assembly is integrated into the cover part to compose an integrated combination which is detachable from the electronic device.

8. An electromechanical assembly according to claim 1, wherein the printed wired foil comprises wiring to provide contact points electrically connecting the electromechanical assembly to a tactile feed back component of the electronic device.

9. An electromechanical assembly according to claim 8, wherein the electromechanical assembly is a touch sensor assembly comprising at least a touch sensor connected to a printed wired foil and means for electrically connecting the touch sensor assembly to the electronic device, wherein the touch sensor assembly is integrated into the cover part to compose an integrated combination which is detachable from the electronic device.

10. An electromechanical assembly according to claim 1, wherein the cover part is exchangeable.

11. An electromechanical assembly according to claim 1, wherein the electronic device is one of the following portable electronic devices:

a mobile phone, a communicator, a portable digital assistant, a palmtop computer, a laptop computer, a web terminal equipment, a digital camera, a game device, an entertainment device, a power source, a health care and a measuring device.

12. A cover part for an electronic device, the electronic device comprising an electromechanical assembly which comprises at least a printed wired foil and connecting means for electrically connecting the electromechanical assembly to the electronic device, and the electronic device comprising means for mechanically connecting the cover part, wherein the electromechanical assembly is arranged to be an insert during an injection molding process to produce the cover part so that the electromechanical assembly and the cover part are arranged to compose an integrated combination which is detachable from the electronic device.

13. A cover part according to claim 12, wherein the electromechanical assembly is integrated into the cover part to compose an integrated combination which is detachable from the electronic device.

14. A cover part according to claim 12, wherein the electromechanical assembly is one of the following assemblies:

an input device assembly, a keypad assembly and a touch sensor assembly.

15. A cover part according to claim 12, wherein the cover part is manufactured by injection moulding.

16. A cover part according to claim 12, wherein the cover part is exchangeable.

17. A cover part according to claim 12, wherein the electronic device is one of the following portable electronic devices:

a mobile phone, a communicator, a portable digital assistant, a palmtop computer, a laptop computer, a web terminal equipment, a digital camera, a game device, an entertainment device, a power source, a health care and a measuring device.

18. A method for manufacturing an electromechanical assembly for an electronic device, the electromechanical assembly comprising at least a printed wired foil, and the electronic device comprising at least one cover part, the electromechanical assembly is arranged to be an insert during an injection molding process to produce the cover part, the method comprising:

electrically connecting a printed wired foil to an electromechanical assembly and to an electronic device having at least one cover part,

mechanically connecting the cover part to the electronic device, and

composing the electromechanical assembly and the cover part to be an integrated combination which is detachable from the electronic device.

19. A method for manufacturing an electromechanical assembly according to claim 18, the method comprising integrating the electromechanical assembly into the cover part to compose an integrated combination which is detachable from the electronic device.

20. A method for manufacturing an electromechanical assembly according to claim 19, wherein the printed wired foil is a multi-layer printed wired foil.

21. A method for manufacturing an electromechanical assembly according to claim 20, wherein the electrically connecting further comprises:

printing with conductive ink the wiring onto the printed wired foil to provide electrical connections to contact points and between the contact points for components of the electromechanical assembly, and to contact points electrically connecting the electromechanical assembly to the electronic device,

printing with non-conductive ink the isolation layers onto the printed wired foil, and

printing with coloured ink decorations onto the printed wired foil.

22. method for manufacturing an electromechanical assembly according to claim 21, wherein the electrically connecting further comprises printing with conductive ink the wiring onto the printed wired foil to provide electrical connections to at least one contact point electrically connecting the electromechanical assembly to a tactile feed back component of the electronic device.

23. A method for manufacturing an electromechanical assembly according to claim 22, wherein the electrically connecting further comprises cutting a hole through the printed wired foil at the contact point to the tactile feedback component to provide electrical connection to the tactile feedback component.

24. A method for manufacturing an electromechanical assembly according to claim 23, wherein the electrically connecting comprises printing a lower surface of a printed foil and processing an upper surface of the printed foil to be finger touchable, and printing an upper surface of a printed wired foil, the printed foil being above the printed wired foil, the method further comprising placing a dome sheet layer between the printed foil and the printed wired foil, wherein the dome sheet is electrically conductive at the concave surface of each dome.

25. A method for manufacturing an electromechanical assembly according to claim 24, wherein the printed foil is a first printed wired foil and the printed wired foil is a second printed wired foil.

26. A method for manufacturing an electromechanical assembly according to claim 25, wherein the method comprises thermoforming of the printed wired foil to a desired shape to generate a formed printed wired foil.

27. A method for manufacturing an electromechanical assembly according to claim 26, wherein the method comprises thermoforming of a combination of the printed foil and the printed wired foil to a desired shape to generate a formed printed wired foil.

28. A method for manufacturing an electromechanical assembly according to claim 27, wherein the method comprises mounting electrical and mechanical components to the formed printed wired foil.

29. A method for manufacturing an electromechanical assembly according to claim 28, wherein the method comprises mounting the connecting means, preferably small cylindrical connectors, by soldering or glueing one end of the connecting means to the wiring of the formed printed wired foil.

30. A method for manufacturing an electromechanical assembly according to claim 29, wherein the mounting mechanical components further comprises mounting a keymat to the formed printed wired foil and printing with conductive ink the wiring onto the keymat to provide electrical connections to contact points and between the contact points for keypad of the electromechanical assembly.

31. A method for manufacturing an electromechanical assembly according to claim 30, wherein the method comprises placing a support layer under the formed printed wired foil, the support layer comprising a rigid light guide emitting the light upward in the place of each dome.

32. A method for manufacturing an electromechanical assembly according to claim 31, wherein the method comprises placing a support layer under the formed printed wired foil, the support layer comprising an electroluminescence foil emitting the light upward in the place of each dome.

33. A method for manufacturing a cover part for an electronic device, the electronic device comprising at least an electromechanical assembly which comprises at least a printed wired foil, the electromechanical assembly is arranged to be an insert during an injection molding process to produce the cover part, wherein the method comprises:

electrically connecting the printed wire foil to the electronic device,

mechanically connecting the cover part to the electronic device, and

composing the electromechanical assembly and the cover part to be an integrated combination which is detachable from the electronic device.

34. A method for manufacturing a cover part according to claim 33, wherein the method comprising integrating the electromechanical assembly into the cover part to compose an integrated combination which is detachable from the electronic device.

35. A method for manufacturing a cover part according to claim 34, wherein the electromechanical assembly comprises a formed printed wired foil and connecting means, preferably small cylindrical connectors, first end of the connecting means electrically connected to the wiring of the formed printed wired foil.

36. A method of manufacturing a cover part according to claim 33, wherein the method further comprises:

inserting the formed printed wired foil on top of a first mould comprising a through hole to a position where the second end of the connecting means are directed towards the first mould,

placing a cover foil on top of the formed printed wired foil,

placing a second mould on top of the cover foil so that a cavity is provided between the second mould and the formed printed wired foil, a lower edge of the second mould following a shape of the formed printed wired foil,

setting the first mould and the second mould against each other so that the lower edge of the second mould is engaged to the cover foil and the combination of the first and second mould is held still, and

injecting molten resin via the through hole to the cavity between the first mould and the cover foil.

37. A method for manufacturing a cover part according to claim 36, wherein the method comprises after injecting, cleaning, preferably grinding, the second end of the connecting means for electrically connecting the electromechanical assembly to the electronic device.

38. A method for manufacturing a cover part according to claim 37, wherein placing a cover foil on top of the formed printed wired foil comprises placing a perforated cover foil on top of the formed printed wired foil comprising a dome sheet layer, wherein a perforation of the cover foil is locating at the location of the dome of the dome sheet, so that the perforated cover foil and the formed printed wired foil with domes compose a solid combination.

39. A method for manufacturing a cover part according to claim 37, wherein the injecting melted plastic further comprises seaming joints between edges of the perforations of the cover foil and the dome sheet during the injection moulding.

40. A method for manufacturing a cover part according to claim 36, wherein the inserting comprises inserting the formed printed wired foil on top of a first mould comprising a through hole and a bump on top and placing the formed printed wired foil to a position where the bump masks the contact points from the electromechanical assembly to the electronic device, and after injection moulding mounting the connecting means to the place of the bumps.

41. A method for manufacturing a cover part according to claim 39, wherein the cover foil is a prefabricated cover part of the electronic device.

42. An apparatus comprising:

a printed wired foil, and

at least one connector for electrically connecting said apparatus to an electronic device having at least one cover part and a mechanical assembly for connecting the cover part to the electronic device,

wherein the apparatus is configured to be an insert during an injection molding process to produce the cover part so that the apparatus and the cover part are configurable to compose an integrated combination which is detachable from the electronic device.

43. The apparatus according to claim 42, wherein the apparatus is integrated into the cover part to compose an integrated combination which is detachable from the electronic device.

44. The apparatus according to claim 42, wherein the printed wired foil is separated from the printed wired board of the electronic device.

45. The apparatus according to claim 42, wherein the printed wired foil comprises:

wiring to provide electrical connections to contact points and between the contact points for components of the apparatus and to contact points electrically connecting by the at least one connector the apparatus to the electronic device,

isolation layers,

decorations, and

electronic and mechanical components mounted on the appropriate contact points onto the printed wired foil.

46. The apparatus according to claim 42, wherein the at least one connector comprises small cylindrical connectors that are soldered or glued to the contact points electrically connecting the apparatus to the electronic device.

47. The apparatus according to claim 46, wherein the apparatus is an input device assembly comprising at least an input device connected to a printed wired foil and at least one connector for electrically connecting the input device assembly to the electronic device, wherein the input device assembly is integrated into the cover part to compose an integrated combination which is detachable from the electronic device.

48. The apparatus according to claim 42, wherein the apparatus is a keypad assembly comprising at least a keypad connected to a printed wired foil and at least one connector for electrically connecting the keypad assembly to the electronic device, wherein the keypad assembly is integrated into the cover part to compose an integrated combination which is detachable from the electronic device.

49. The apparatus according to claim 42, wherein the printed wired foil comprises wiring to provide contact points electrically connecting the apparatus to a tactile feed back component of the electronic device.

50. The apparatus according to claim 49, wherein the apparatus is a touch sensor assembly comprising at least a touch sensor connected to a printed wired foil and at least one connector for electrically connecting the touch sensor assembly to the electronic device, wherein the touch sensor assembly is integrated into the cover part to compose an integrated combination which is detachable from the electronic device.

51. The apparatus according to claim 42, wherein the cover part is exchangeable.

52. The apparatus according to claim 42, wherein the electronic device is one of the following portable electronic devices:

a mobile phone, a communicator, a portable digital assistant, a palmtop computer, a laptop computer, a web terminal equipment, a digital camera, a game device, an entertainment device, a power source, a health care and a measuring device.

53. A cover part for an electronic device, the electronic device comprising an electromechanical assembly which comprises at least a printed wired foil and at least one connector for electrically connecting the electromechanical assembly to the electronic device, and the electronic device further comprising a mechanical coupler for mechanically connecting the cover part, wherein the electromechanical assembly is arranged to be an insert during an injection molding process to produce the cover part so that the electromechanical assembly and the cover part are arranged to compose an integrated combination which is detachable from the electronic device.

54. The cover part according to claim 53, wherein the electromechanical assembly is integrated into the cover part to compose an integrated combination which is detachable from the electronic device.

55. The cover part according to claim 53, wherein the electromechanical assembly is one of the following assemblies:

an input device assembly, a keypad assembly and a touch sensor assembly.

56. The cover part according to claim 53, wherein the cover part is manufactured by injection moulding.

57. The cover part according to claim 53, wherein the cover part is exchangeable.

58. The cover part according to claim 53, wherein the electronic device is one of the following portable electronic devices:

a mobile phone, a communicator, a portable digital assistant, a palmtop computer, a laptop computer, a web terminal equipment, a digital camera, a game device, an entertainment device, a power source, a health care and a measuring device.

59. An apparatus comprising:

a printed wired foil, and

means for electrically connecting said apparatus to an electronic device having at least one cover part and a mechanical assembly for connecting the cover part to the electronic device,

wherein the apparatus is configured to be an insert during an injection molding process to produce the cover part so that the apparatus and the cover part are configurable to compose an integrated combination which is detachable from the electronic device.

60. The apparatus according to claim 59, wherein the apparatus is integrated into the cover part to compose an integrated combination which is detachable from the electronic device.