Injection molded control panel with in-molded decorated plastic film that includes an internal connector

• US 9,030,837 B2
• Filed: 10/06/2011
• Issued: 05/12/2015
• Est. Priority Date: 06/10/2011
• Status: Active Grant

• Current Assignee: E2IP Technologies Incorporated
• Original Assignee: Scott Moncrieff
• Inventors: Moncrieff, Scott
• Primary Examiner(s): Haughton, Anthony
• Assistant Examiner(s): FENG, ZHENGFU J
• Application Number:
  US13/267,802
• Publication Number:
  US 20120314349A1
• Time in Patent Office: 1,314 Days
• Field of Search: 361/679.01, 361/627, 361/762, 156/64
• US Class Current: 361/762
• CPC Class Codes: B29C 2045/14532 injecting between two sheets
• CPC Class Codes: B29C 45/14467 Joining articles or parts of a single article B29C45/14377, B29C45/14385, B29C45/14581, B29C45/14614 and B29C45/006 take precedence
• 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: D06F 34/28 Arrangements for program selection, e.g. control panels therefor; Arrangements for indicating program parameters, e.g. the selected program or its progress
• CPC Class Codes: G02B 6/0001 specially adapted for lighting devices or systems lighting or signalling on vehicles using light guides B60Q1/00; lighting devices for vehicle dashboards B60Q3/10; lighting devices for vehicle interior using light guides B60Q3/62; lighting devices mounted on the vehicle rear part using light guides F21S43/235; measuring arrangements having light conducting pointers G01D13/265; illumination of liquid crystal displays G02F1/1336; illuminated signs G09F13/00
• CPC Class Codes: H05K 1/0298 Multilayer circuits
• CPC Class Codes: H05K 1/16 incorporating printed electric components, e.g. printed resistor, capacitor, inductor
• CPC Class Codes: H05K 1/18 Printed circuits structurally associated with non-printed electric components H05K1/0201, H05K1/023, H05K1/0243, and H05K1/16 take precedence
• CPC Class Codes: H05K 1/181 associated with surface mounted components
• 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 2201/10507 Involving several components
• CPC Class Codes: H05K 3/0014 Shaping of the substrate, e.g. by moulding
• CPC Class Codes: H05K 3/12 using thick film techniques, e.g. printing techniques to apply the conductive material or similar techniques for applying conductive paste or ink patterns
• CPC Class Codes: H05K 3/284 for encapsulating mounted components H05K1/185 takes precedence
• CPC Class Codes: H05K 3/30 Assembling printed circuits with electric components, e.g. with resistor
• CPC Class Codes: H05K 5/0017 with operator interface units
• CPC Class Codes: H05K 5/0243 for decorative purposes
• CPC Class Codes: Y10T 29/49004 including measuring or testing of device or component part

Abstract

Provided are systems and methods for a control assembly including: a first film that is in-molded that includes decorative graphics, a front surface and a rear surface; and a second film molded to the rear surface of the first film having a printed circuit that includes sensors, control circuits and interconnects and a front and rear surface; and an internal connector.

Claims

1. A control assembly comprising:

a first film that is in-molded to a front surface of a resin core, the first film including decorative graphics, a front surface and a rear surface;

a second film comprising a printed circuit that includes sensors, control circuits and interconnects disposed on a front surface of the second film; and

an internal connector,

wherein the front surface of the second film is molded to a rear surface of the resin core, and

wherein the internal connector is included in the second film and is precut to its finished geometry yet still partially attached to the second film via perforations or discontinuous connections such that it can be partially separated from the second film.

2. The control assembly of claim 1, wherein the printed circuit includes at least one of capacitive touch sensors, proximity sensors, water detect sensor, functional antennas, and other electronic sensors,

wherein the sensors and antennas each comprise one or more surface mounted electronic components.

3. The control assembly of claim 1, further comprising a layer of resin between the first and second films.

4. The control assembly of claim 1, further comprising a plastic panel mounted on the rear surface of the second film.

5. The control assembly of claim 1, wherein the second film is further comprised of surface mounted electronic components.

6. The control assembly of claim 1, wherein the second film further comprises in-molded lighting and associated components with light guide features.

7. The control assembly of claim 1, wherein the second film further comprises a display.

8. The control assembly of claim 7, wherein the display includes a touch screen.

9. The control assembly of claim 2, wherein the surface mounted electronic components comprise one or more LEDS, resistors, capacitors, transistors, or programmable integrated circuits.