Part obtained by an IME-type manufacturing process comprising at least one connector on one of its faces, manufacturing process for such a part

Abstract

Part obtained by an IME-type manufacturing process comprising at least one connector on one of its faces, manufacturing process for such a part. The invention relates to a part comprising a flexible support (14), a body (12) overmolded by injection on one face (14.2) of the flexible support (14), and at least one connector (20) positioned on one of the faces of the part, the pins (30, 32) being substantially perpendicular to the first and second faces (14.1, 14.2) of the flexible support (14), the connector (20) comprising at least one pin (40) integral with the base (22) projecting from the face (22.1) of the base (22) oriented towards the flexible support (14), each pin (40) having a length such that it is at least partially embedded in the body (12) during its injection. The invention also relates to a method for manufacturing such a part. Figure 1

Description

Title of the invention: Part obtained by an IME-type manufacturing process comprising at least one connector on one of its faces, manufacturing process for such a part

[0001] The present application relates to a part obtained by an IME-type manufacturing process comprising at least one connector on one of its faces and to a manufacturing process for such a part.

[0002] According to one embodiment, a method for obtaining a part, called the IME process for (in-mold electronics), includes a step of printing a conductive track on a first face of a flexible film-shaped support, a step of placing electronic components on the flexible support, a step of thermoforming the flexible support to conform it according to the geometry of the part to be produced, a step of positioning the formed flexible support in a mold and a step of injecting a material into the mold in order to obtain the part by overmolding.

[0003] At the end of the manufacturing process, the part comprises a first face at the level of which the flexible support is positioned, a second face at the level of which a decorative film is positioned, and a peripheral edge connecting the first and second faces.

[0004] According to one embodiment, the part includes at least one connection ribbon which opens at the edge of the part after the injection step and at least one connector connected to this connection ribbon, positioned at the edge of the part and connected to the latter by gluing for example after the injection step.

[0005] Even though it allows for a solid connection between the connector and the part, this solution is not entirely satisfactory because the connector tends to increase the bulk of the part at its periphery, which tends to complicate its integration.

[0006] The present invention aims to remedy all or part of the drawbacks of the prior art.

[0007] For this purpose, the invention relates to a part comprising a flexible support which has first and second faces, a body overmolded by injection on the second face of the flexible support and at least one connector which includes a base having a first face and at least two pins passing through the base and each having an end connected to a conductive track affixed to the first or second face of the flexible support.

[0008] According to the invention, the pins are substantially perpendicular to the first and second faces of the flexible support. In addition, the connector comprises at least a spike attached to the base and protruding from the first face oriented towards the flexible support, each spike having a length such that it is at least partially embedded in the body during its injection.

[0009] This solution allows the connector to be positioned on one of the faces of the part, each pin embedded in the body ensuring a solid mechanical connection between the connector and the rest of the part.

[0010] Other features and advantages will become apparent from the following description of the invention, given by way of example only, with reference to the accompanying drawings, among which:

[0011] [Fig-1] is a cross-section of a part obtained by an IME-type process incorporating a connector on one of its faces,

[0012] [Fig.2] is a schematic representation of different stages of a process of the type IME illustrating one embodiment of the invention,

[0013] [Fig.3] is a cross-section of a mold and connector illustrating one embodiment of the invention,

[0014] [Fig.4] is a top view of the mold and connector visible in [Fig.3],

[0015] [Fig. 5] is a cross-section of a flexible support and pins illustrating a mode of realization of the invention,

[0016] [Fig.6] is a top view of the flexible support and pins visible on [Fig.5],

[0017] [Fig.7] is a top view of a mold, on which a connector is positioned and a flexible support, illustrating one embodiment of the invention,

[0018] [Fig.8] is a cross-section of a mold, a connector and a flexible support, before a injection stage, illustrating one embodiment of the invention,

[0019] [Fig.9] is a perspective view of a connector illustrating one embodiment of the invention,

[0020] [Fig. 10] is a side view of the connector, visible in [Fig. 9], fixed to a flexible support illustrating one embodiment of the invention,

[0021] [Fig. 11] is a cross-section of a part obtained by an IME type process integrating a connector at one of its faces.

[0022] According to an embodiment visible in figures 1 and 2, a part 10 has a front face 10.1 (visible when the part 10 is integrated into an environment), a rear face 10.2 and an edge connecting the front and rear faces 10.1, 10.2.

[0023] The part 10 comprises a body 12, made of an injection-molded material, having a first face 12.1 oriented towards the front face 10.1 and a second face 12.2 oriented towards the rear face 10.2, as well as at least one flexible film-shaped support 14, positioned at the rear face 10.2, having a first face 14.1 oriented towards the rear face 10.2 and a second face 14.2 oriented towards the body 12. In one configuration, the first face 14.1 of the flexible support 14 forms the face rear 10.2 of part 10. The second face 14.2 of the flexible support 14 is in contact with the second face 12.2 of the body 12.

[0024] According to one configuration, the part 10 comprises at least one decorative layer 16, in the form of a film and positioned at the front face 10.1, which has a first face 16.1 oriented towards the front face 10.1 and a second face 16.2 oriented towards the body 12. According to one configuration, the first face 16.1 of the decorative layer 16 forms the front face 10.1 of the part 10. The second face 16.2 of the decorative layer 16 is in direct contact with the first face 12.1 of the body 12.

[0025] The part 10 includes at least one conductive track 18 affixed to the first or second face 14.1, 14.2 of the flexible support 14.

[0026] According to a first embodiment visible in [Fig.2], the part 10 comprises at least a first conductive track 18 affixed against the first face 14.1 of the flexible support 14 and at least a second conductive track 18' affixed against the second face 14.2.

[0027] According to a second embodiment visible in [Fig.5], the part 10 comprises at least one conductive track 18 on one of the first and second faces 14.1, 14.2 only, in particular on the first face 14.1 of the flexible support 14.

[0028] According to one configuration, the part 10 includes at least one electronic component connected to the first or second conductive track 18, 18'.

[0029] Part 10 includes at least one connector 20 positioned at the rear face 10.2 of part 10, spaced from its edge.

[0030] Each connector 20 comprises a base 22 which has first and second faces 22.1, 22.2 and an edge 22.3 connecting the first and second faces 22.1, 22.2. The first and second faces 22.1, 22.2 are substantially parallel to each other. In operation, the first face 22.1 is oriented towards the flexible support 14. In one configuration, the edge 22.3 has a truncated pyramid shape. Of course, the invention is not limited to this geometry for the edge 22.3.

[0031] The connector 20 comprises a tubular housing 24 integral with the base 22 and projecting from the second face 22.2. The tubular housing 24 and the base 22 form a housing 26. In one configuration, the tubular housing 24 has a rectangular or square cross-section with rounded corners in a plane parallel to the first and second faces 22.1, 22.2 of the base 22. Of course, the invention is not limited to this geometry for the tubular housing 24.

[0032] The base 22 and the tubular housing 24 are not described further as they may be identical to those of the prior art.

[0033] According to one assembly method, the connector 20 is attached to the flexible support 14 by gluing. For this purpose, a layer of glue 28 is interposed between the flexible support 14 and the connector 20, more particularly between the flexible support 14 and the base 22 of the connector 20. According to a configuration visible on [Fig.9], the base 22 includes a groove 29, recessed relative to the first face 22.1, configured to partially house the glue 28 and form a sealing bead around the pins.

[0034] This connector 20 comprises at least two pins 30, 32, substantially perpendicular to the first and second faces 14.1, 14.2 of the flexible support 14, each having a first end 30.1, 32.1 connected to the first or second conductive track 18, 18' and a second end 30.2, 32.2 located in the housing 26, the two pins 30, 32 passing through the base 22. For this purpose, the latter comprises, for each pin 30, 32, a through hole 22.4 which opens at the level of the first and second faces 22.1, 22.2 of the base 22.

[0035] According to one embodiment, at least one pin 30, 32 has, at its first end 30.1, 32.1, a plate 34 pressed against the first or second conductive track 18, 18' and connected to it. Depending on the configuration, the plate 34 may be soldered or glued to the first or second conductive track 18, 18'. In one configuration, a dot of glue 36 (or a layer of glue) made of a conductive material is interposed between the plate 34 and the first or second conductive track 18, 18' to connect them.

[0036] According to an embodiment visible in figures 1 and 8, the pins 30, 32 are connected to the first conductive track 18 located on the first face 14.1 of the flexible support 14 and oriented towards the connector 20. In this case, the pins 30, 32 do not pass through the flexible support 14.

[0037] According to another embodiment, the pins 30, 32 are connected to the second conductive track 18' located on the second face 14.2 of the flexible support 14. In this case, the flexible support 14 includes a through hole for each pin 30, 32.

[0038] According to another embodiment visible in [Fig.2], at least one first pin 30 is connected to the first conductive track 18 located on the first face 14.1 of the flexible support 14 and oriented towards the connector, at least one second pin 32 is connected to the second conductive track 18' located on the second face 14.2 of the flexible support 14, opposite to the first face 14.1. In this case, the flexible support 14 includes a through hole 38 for each second pin 32 to allow it to pass through the flexible support 14.

[0039] According to a particular feature of the invention, the connector 20 includes at least one pin 40, projecting from the first face 22.1 of the base 22 of the connector 20, dimensioned to pass through the flexible support 14 and to be at least partially embedded in the body 12.

[0040] By pin, we mean an element attached to the base 22 of the connector 20 and projecting from its first face 20.1, regardless of its shape and section.

[0041] Each pin 40 has a free end 40.1 distant from the base 22 and a length (distance separating the base 22 and the free end 40.1 of the pin 40) such that the free end 40.1 is located at the level of the first face 12.1 of the body 12 opposite the flexible support 14 and comes into contact with the decoration layer 16 or with a mold during the ejection step.

[0042] According to one arrangement, at least one stud 40 has a slightly frustoconical shape and a slightly rounded free end 40.1. Alternatively, at least one stud 40 has a rivet shape.

[0043] According to one arrangement, the connector 22 comprises several pins, including four positioned at the level near the corners of the base 22.

[0044] The base 22, the tubular housing 24 and the pin(s) form a single piece.

[0045] Of course, the invention is not limited to this geometry or this number for the pins.

[0046] For each pin 40, the flexible support 14 includes a through hole 42 which connects the first and second faces 14.1, 14.2 of the flexible support 14 and allows the pin 40 to pass through it.

[0047] Regardless of the embodiment, the part 10 comprises a flexible support 14 having first and second faces 14.1, 14.2, a body 12 overmolded by injection molding onto the first face 14.1, at least one conductive track 18 affixed to the first or second face 14.1, 14.2 of the flexible support 14, at least one connector 20 comprising a base 22 having a first face 22.1 oriented towards the flexible support 14, and at least two pins 30, 32 passing through the base 22 and each having an end 30.1, 32.1 connected to a conductive track 18 affixed to one of the faces 14.1, 14.2 of the flexible support 14. According to the invention, the connector 20 comprises at least one pin 40 integral with the base 22 and projecting from the first face 22.1. In addition, the flexible support 14 includes a through orifice 42 for each spike 40, the latter having a length such that it is partially embedded in the body 12 during its injection.

[0048] Each pin 40 helps to strengthen the connection between the connector 20 and the rest of the part 10 and to position the connector 20 at the rear face 10.2 and not at the periphery of the part 10.

[0049] As illustrated in [Fig.2], a bead of glue 44 can be added around the periphery of the base 22 to reinforce the mechanical bond between the connector 20 and the flexible support 14.

[0050] According to one method, a manufacturing process includes a step of placing at least one connector 20 in a cavity 46 of a first mold 48 which has a face 48.1 shaped like the rear face 10.2 of the part to be produced, as illustrated in Figures 3 and 4. The cavity 46 is configured to immobilize the connector 20 in a single, specific position, the first face 22.1 of the base 22 being substantially aligned with the face 48.1 of the first mold 48. To this end, the cavity 46 includes a portion that cooperates with the truncated pyramid-shaped edge 22.3 of the base 22. For reference, the edge 22.3 forms an angle of approximately 45° with the first face 22.1 of the base. The fact that the edge 22.3 and the cavity 46 have flared shapes allows for the centering of the connector 20 and its immobilization relative to the first mold 48 in a specific position, particularly during the injection of the body 12.

[0051] According to one configuration, the footprint 46 includes shapes that fit those of the connector 20, including a protruding shape 50 configured to fit into the housing 26 of the connector 20. This protruding shape 50 includes a hole 50.1 for each pin 30, 32 in order to house and guide it.

[0052] According to one configuration, the manufacturing process includes a step of applying a layer of glue 28 to the first face 22.1 of the base 22 of the connector 20 before the flexible support 14 is put in place.

[0053] In parallel, the manufacturing process includes a step of making each conductive track 18, 18' on the flexible support 14 and possibly a step of placing at least one electronic component.

[0054] As illustrated in part (A) of [Fig.2], the manufacturing process includes a step of drilling the flexible support 14 which aims to create a through hole 42 for each pin 40 of the connector 20. For each pin 30 which passes through the flexible support 14, the drilling step aims to create a through hole 38.

[0055] Next, the manufacturing process includes a step of setting up the pins 30, 32 by connecting them to the conductive track(s) 18, 18', as illustrated in part (B) of [Fig.2] or figures 5 and 6.

[0056] The manufacturing process may include a thermoforming step of the flexible support 14 to conform it according to the geometry of the back face 10.2 of the part 10 to be produced.

[0057] The manufacturing process includes a step of placing the flexible support 14, provided with the pins 30, 32, in the first mold 48, against the face 48.1 of the first mold 48. During this step, the pins 40 are positioned in the through holes 42 of the flexible support 14 and the pins 30, 32 are inserted into the through holes 22.4 of the base 22 of the connector 20 and the optional holes 50.1 of the protruding form 50 of the first mold 48. The first mold 48 may include pins 52 configured to fit into holes in the flexible support 14 to facilitate the positioning of the latter in the first mold 48, as illustrated in [Fig. 7].

[0058] The manufacturing process includes a step of setting up a second mold 54 which has a face 54.1 shaped like the front face 10.1 of the part 10 to be produced, the first and second molds 48, 54 delimiting a cavity identical to the part 10 to be produced when they are closed.

[0059] If part 10 includes a decoration film 16, the latter is positioned against face 54.1 of the second mold 54, as illustrated in [Fig.8], before closing the molds 48, 54.

[0060] Similar to an IME-type process, the manufacturing process includes an injection step of the body 12, as illustrated in part (C) of [Fig. 2], as well as cooling and demolding steps. This process makes it possible to obtain a strong mechanical bond between the body 12, the flexible support 14, and the optional decorative film 16. The pins 40 are also strongly bonded to the body 12, which ensures a very strong mechanical bond between the body 12 and the connector 20, even if the latter is positioned on the rear face 10.2 of the part 10.

[0061] As illustrated in part (D) of [Fig.2], the manufacturing process may include a step of applying a bead of glue 44 around the periphery of the base 22 to reinforce the mechanical connection between the connector 20 and the flexible support 14 and / or the seal between the connector 20 and the flexible support 14.

[0062] Of course, the invention is not limited to the embodiments described above. As illustrated in [Fig. 11], the body 12 could be interposed between the base 22 of the connector 20 and the flexible support 14. Regardless of the embodiment, the connector 20 comprises at least one pin 40 integral with the base 22 and projecting from the first face 22.1 oriented towards the flexible support 14, each pin 40 having a length such that it is at least partially embedded in the body 12 during its injection.

Claims

Demands

1. Part comprising: a. a flexible support (14) having first and second faces (14.1, 14.2), b. a body (12) overmolded by injection on the second face (14.2) of the flexible support (14), c. at least one connector (20) comprising a base (22) having a first face (22.1) and at least two pins (30, 32) passing through the base (22) and each having an end (30.1, 32.1) connected to a conductive track (18) affixed to the first or second face (14.1, 14.2) of the flexible support (14), d. characterized in that the pins (30, 32) are substantially perpendicular to the first and second faces (14.1, 14.2) of the flexible support (14), e. and in that the connector (20) includes at least one pin (40) integral with the base (22) and projecting from the first face (22.1) oriented towards the flexible support (14), each spike (40) having a length such that it is at least partially embedded in the body (12) during its injection.

2. Part according to claim 1, characterized in that the flexible support (14) includes a through hole (42) for each pin (40).

3. Part according to claim 2, characterized in that each pin (40) has a free end (40.1) distant from the base (22) and a length such that the free end (40.1) is located at a face (12.1) of the body (12) opposite the flexible support (14).

4. Part according to any one of claims 2 to 3, characterized in that the part comprises a layer of glue (28) intercalated between the flexible support (14) and the connector (20).

5. Part according to any one of the preceding claims, characterized in that the connector (20) comprises several pins (40).

6. Part according to any one of the preceding claims, characterized in that at least one stud (40) has a slightly frustoconical or rivet shape and a slightly rounded free end (40.1).

7. Part according to any one of the preceding claims, characterized in that the pins (30, 32) are connected to a first conductive track (18) located on the first face (14.1) of the flexible support (14) and oriented towards the connector (20).

8. A part according to any one of claims 1 to 6, characterized in that at least one first pin (30) is connected to a first conductive track (18) located on the first face (14.1) of the flexible support (14) and oriented towards the connector (20) and in that at least one second pin (32) is connected to a second conductive track (18') located on the second face (14.2) of the flexible support (14), opposite to the first face (14.1), the flexible support (14) having a through hole (38) for each second pin (32) to allow it to pass through the flexible support (14).

9. A method for manufacturing a part according to any one of the preceding claims, characterized in that the method comprises: a. a step of placing at least one connector (20) in a cavity (46) of a first mold (48), b. a step of making each conductive track (18, 18') on a flexible support (14), c. a step of setting up the pins (30, 32) by connecting them to the conductive track(s) (18, 18'), d. a step of setting up a second mold (54), the first and second molds (48, 54) defining a cavity identical to the part (10) to be produced when the first and second molds (48, 54) are closed, the flexible support (14) being positioned in the cavity, the pins (30, 32) being inserted into through holes (22.4) in the base (22) of the connector (20), e. a body injection step (12) as well as cooling and demolding steps.

10. Method according to the preceding claim, characterized in that the imprint (46) comprises shapes which fit those of the connector (20) as well as a hole (50.1) configured to house and guide each pin (30, 32).

11. A method according to any one of claims 9 to 10, characterized in that the method comprises a step of perforating the flexible support (14) to create a through hole (42) for each stud (40)

12. of the connector (20) during the injection step, each pin (40) of the connector (20) being positioned in a through hole (42) of the flexible support (14). Method according to the preceding claim, characterized in that it includes a step of placing a layer of glue (28) on the first face (22.1) of the base (22) of the connector (20) before the step of placing the flexible support (14).

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