Component Having A Hard Foam Body And An Electric And/Or Electronic Functional Element

• US 20080093890A1
• Filed: 08/12/2005
• Published: 04/24/2008
• Est. Priority Date: 08/13/2004
• Status: Abandoned Application

• Current Assignee: F.S. Fehrer Automotive Systems GmbH, Intedis GmbH & Co. KG
• Original Assignee: Intedis GmbH & Co. KG
• Inventors: Kittner, Manfred, Wagemann, Rolf, Cilensek, Carstein, Mehling, Walter
• Application Number:
  US11/573,599
• Publication Number:
  US 20080093890A1
• Time in Patent Office: Days
• US Class Current: 296/191
• CPC Class Codes: B60Q 3/233 Seats; Arm rests; Head rests
• CPC Class Codes: B60Q 3/54 Lighting devices embedded in interior trim, e.g. in roof liners
• CPC Class Codes: B60Q 3/64 for a single lighting device
• CPC Class Codes: B60Q 3/745 using lighting panels or mats, e.g. electro-luminescent panels, LED mats
• CPC Class Codes: B60R 11/02 for radio sets, television sets, telephones, or the like; Arrangement of controls thereof
• CPC Class Codes: B60R 13/02 Internal Trim mouldings ; Internal Ledges; Wall liners for passenger compartments; Roof liners B60R13/01 takes precedence ; padded linings for the vehicle interior B60R21/04; arrangements or adaptations of floor mats or carpets in vehicles B60N3/04; internal lining for trains B61D17/18
• 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 2201/0116 Porous, e.g. foam
• 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

Abstract

The present invention relates to a component (07, 25, 33), particularly for a vehicle (01), the component (07, 25, 33) being produced from a foamed polymer with formation of a hard foam body (11, 26, 36, 45, 52, 60, 66), and at least one electric and/or electronic functional element (10, 15, 16, 17, 18, 19, 20, 21, 35) being provided on the component (07, 25, 33, 50). A flat conductor set (08, 27, 34, 44, 51, 57, 67, 71) is provided for the electrically conductive contacting of the functional element (10, 15, 16, 17, 18, 19, 20, 21, 28, 35), in which at least two printed conductors (13) are attached jointly on or in an essentially planar and deformable insulator element (12, 30, 37), the flat conductor set (08, 27, 34, 44, 51, 57, 67, 71) being at least partially embedded in foam in the hard foam body (11, 26, 36, 45, 52, 60, 66).

Claims

1. A component (07, 25, 33, 50), particularly for a vehicle (01), the component (07, 25, 33, 50) being produced from a foamed polymer with formation of a hard foam body (11, 26, 36, 45, 55, 60, 66), and at least one electric and/or electronic functional element (10, 15, 16, 17, 18, 19, 20, 21, 35, 52, 53) being provided on the component (07, 25, 33, 50),

characterized in that

a flat conductor set (08, 27, 34, 44, 51,57, 67, 71) is provided for the electrically conductive contacting of the functional element (10, 15, 16, 17, 18, 19, 20, 21, 28, 35, 52, 53), in which at least two printed conductors (13) are attached jointly on or in an essentially planar and deformable insulator element (12, 30, 37), the flat conductor set (08, 27, 34, 44, 51, 57, 67, 71) being at least partially embedded in foam in the hard foam body (11, 26, 36, 45, 50, 60, 66).

2. The component according to claim 1,

characterized in that

the flat conductor set (08a) has recesses (23) and/or slots (24), which are penetrated by foam during formation of the hard foam body (11).

3. The component according to claim 1,

characterized in that

the electric and/or electronic functional element (10, 15, 16, 17, 18, 19, 20, 21 28, 35) is attached to the flat conductor set (08, 27, 34, 44, 57, 67, 71), particularly soldered on.

4. The component according to claim 1,

characterized in that

the electric and/or electronic functional element (10, 15, 16, 17, 18, 19, 20, 21 28, 35, 52, 53) is at least partially embedded in foam in the hard foam body (11, 26, 36, 45, 50, 60, 66).

5. The component according to claim 1,

characterized in that

the flat conductor set (51) is deformed to form a three-dimensional shape, in particular folded along at least one folding edge or twisted around at least one axis of torsion or bent or bulged along at least on e bending line, and together with the deformed part is embedded in foam in the component (50).

6. The component according to claim 1,

characterized in that

the component is implemented as a housing.

7. The component according to claim 1,

characterized in that

the component (7) is implemented as a paneling element, in particular a set panel, a door panel, a sunroof panel, a trunk panel, a cockpit panel, a dashboard support, or a roof lining element.

8. The component according to claim 1,

characterized in that

the component (07, 25, 33) has a cover film (14, 30, 37), particularly on the visible side of a paneling element.

9. The component according to claim 8,

characterized in that

the flat conductor set (34) is attached to the cover film (37) and particularly together with the cover film (37) has foam applied behind to form the hard foam body (36).

10. The component according to claim 1,

characterized in that

the hard foam body (11, 26, 36, 45, 60, 66) is foamed from an electrically insulating polymer, in particular based on polyurethane.

11. The component according to claim 1,

characterized in that

the insulator element is implemented as an insulator film (12, 30, 37).

12. The component according to claim 11,

characterized in that

no additional cover for insulating the printed conductors (13), in particular no second insulator film, is provided on the side of the printed conductors (13) facing away from the insulator film (12, 30, 37).

13. The component according to claim 11,

characterized in that

the flat conductor set is implemented as an FPC (08, 27, 34, 44, 57, 67, 71), whose flat conductor film is particularly equipped with electronic parts.

14. The component according to claim 1,

characterized in that

the insulator element is implemented as an electrically insulating sheath, which encloses the printed conductors on all sides.

15. The component according to claim 14,

characterized in that

the flat conductor set is implemented as an FPC.

16. The component according to claim 1,

characterized in that

the functional element is implemented as a lamp (10, 21, 28, 35), in particular as an LED.

17. The component according to claim 16,

characterized in that

the lamp (28) is situated on a surface of the component (25), particularly facing away from the visible side of the component (25).

18. The component according to claim 17,

characterized in that

the light generated by the lamp (10, 28, 35) is relayed using a light guiding element (31, 40, 42).

19. The component according to claim 18,

characterized in that

the light guiding element (31, 40, 42) extends through the hard foam body (11, 26).

20. The component according to claim 16,

characterized in that

the lamp (35) is situated in the interior of the hard foam body (36), a light guiding element (40) being provided in or on the hard foam body (36), using which the light generated by the lamp (35) is relayed to a light exit opening (39).

21. The component according to claim 16,

characterize in that

the lamp (10) is situated on a cable tail (09) of the flat conductor set (08) projecting from the hard foam body (11).

22. The component according to claim 21,

characterized in that

the cable tail (09) carrying the lamp (10) is fixed on the component (07) after the curing of the hard foam body (11).

23. The component according to claim 22,

characterized in that

the lamp (10) provided on the cable tail (09) is fixed on a concealed surface of the component (07), a light guiding element (42) being provided on the component (07), using which the light generated by the lamp (10) is relayed through the hard foam body to a light exit opening (41).

24. The component according to claim 18,

characterized in that

the light guiding element is implemented as a light guiding prism (22, 31, 40) or an optical fiber (42).

25. The component according to claim 18,

characterized in that

the light guiding element (40) is at least partially embedded in foam in the hard foam body (36).

26. The component according to claim 18,

characterized in that

the light guiding element (42) is fastened subsequently to the hard foam body (11), particularly snapped in.

27. The component according to claim 16,

characterized in that

the lamp (10) is situated on a component (07), in particular on a seat panel, in such a way that the foot space (18) in a vehicle (01) may be illuminated using the lamp (07).

28. The component according to claim 16,

characterized in that

the lamp is situated on a component, in particular on a sunshade, in such a way that a makeup mirror in the vehicle may be illuminated using the lamp.

29. The component according to claim 1,

characterized in that

the functional element is implemented as a heating unit (15).

30. The component according to claim 29,

characterized in that

the heating unit (15) is implemented as a film heater integrated in the flat conductor set (08).

31. The component according to claim 29,

characterized in that

the heating unit (15) is situated on a seat panel (07) in such a way that, using the heating unit (15), the knee area of the passengers (05) on the rear bench seat (06) of a vehicle (01) may be heated.

32. The component according to claim 1,

characterized in that

the functional element is implemented as a sensor (16).

33. The component according to claim 32,

characterized in that

the sensor (16) operates contactlessly and is completely embedded in the hard foam body (11), in particular, the sensor is implemented as a capactive sensor (16).

34. The component according to claim 32,

characterized in that

the sensor (16) is situated on a seat panel (07) in such a way that contact of the seat panel (16) with body parts or objects may be detected using the sensor (16) to form a pinch protector.

35. The component according to claim 32,

characterized in that

the sensor is situated on a seat panel in such a way that the seat occupancy of a vehicle seat may be detected using the sensor.

36. The component according to claim 1,

characterized in that

the functional element is implemented as a switch.

37. The component according to claim 36,

characterized in that

the switch may be actuated contactlessly an is completely embedded in the hard foam body, in particular, the switch is implemented as a capacitive switch.

38. The component according to claim 1,

characterized in that

the functional element is implemented as control and/or regulatory electronics (17, 18), in particular for dimmable activation of a light element, or for temperature regulation of a heating element, or for analyzing the measured signals of a sensor.

39. The component according to claim 1,

characterized in that

an end, in particular a cable tail (10, 47) of the flat conductor (08, 44) is guided out of the hard foam body (11, 45) in a partition plane defined by the parts (48, 49) of a foaming mold (46).

40. The component according to claim 1,

characterized in that

a seal element (56), in particular a seal stopper, is embedded in foam in the outer surface of the hard foam body (60), a recess or depression being sealed by the seal element (56) in a foaming mold (61) during the foaming of the hard form body (60), and the flat conductor set (62) being guided through a bush in the seal element (56) out of the hard foam body (60) in the recess or depression.

41. The component according to claim 40,

characterized in that

the seal element (56) is implemented in two parts.

42. The component according to claim 41,

characterized in that

the two parts (58, 59) of the seal element (56) may be separated from one another along a particularly planar partition line.

43. The component according to claim 40,

characterized in that

the seal element (56) is only partially embedded in foam, the seal element (56) tapering at least slightly toward the embedded part starting from the embedded part.

44. The component according to claim 40,

characterized in that

the seal element (56) has a flange (63) embedded in foam.

45. The component according to claim 40,

characterized in that

a plug (68, 70, 75, 77, 79) is attached to at least one end of the flat conductor set (67, 71), at least one plug element (72, 76, 78, 80) being provided on a plug (68, 70, 75, 77, 79), via which a printed conductor (13) of the flat conductor set (67, 71) may be electrically contacted.

46. The component according to claim 45,

characterized in that

the plug (68, 70, 75, 77, 79) has a rounded outer contour.

47. The component according to claim 45,

characterized in that

the plug (68, 70, 75, 77, 79) is partially embedded in foam in the hard foam body.

48. The component according to claim 47,

characterized in that

the plug (68, 70, 75, 77, 79) has a closed peripheral sealing surface (74, 81), which comes to rest against the interior of a foaming mold to form a sealing line during the foaming of the hard foam body and seals off the mold cavity of the foaming mold.

49. The component according to claim 48,

characterized in that

the closed peripheral sealing surface (74, 81) has a rounded outer contour.

50. The component according to claim 48,

characterized in that

the sealing surface (74, 81) is formed by a special seal element, in particular a separate sealing ring or a molded-on sealing lip or a molded-on sealing bead.

51. The component according to claim 48,

characterized in that

the closed peripheral sealing surface (74, 81) runs in a sealing plane, the plug elements of the plug penetrating through the sealing plane.

52. The component according to claim 51,

characterized in that

the sealing plane formed by the peripheral sealing surface (81) extends diagonally to the external surface of the hard foam body.

53. The component according to claim 45,

characterized in that

the contact surfaces, which may be electrically contacted, of the plug elements (76, 80), extend parallel to the external surface of the hard foam body.

54. The component according to claim 45,

characterized in that

the contact surfaces, which may be electrically contacted, of the plug elements (72) extend perpendicularly to the external surface of the hard foam body.

55. The component according to claim 45,

characterized in that

the contact surfaces, which may be electrically contacted, of the plug elements (78) extend diagonally to the external surface of the hard foam body.

56. The component according to claim 45,

characterized in that

the plug elements (76, 78, 80) are bent in steps.

57. A plug (68, 70, 75, 77, 79) which may be embedded in foam, in particular to produce a component according to claim 45.