Moulded part

Abstract

The invention relates to a molded part (1) comprising an electrically conductive functional layer (11), at least two spaced-apart electrodes (12) connected to the electrically conductive functional layer (11) for supplying electric current into the functional layer (11) and a component carrier (10) made of plastic material on which the functional layer (11) is applied, wherein the electrodes (12) are integrated into the surface of the component carrier (10) adjacent to the functional layer (11) and are electrically contacted with the functional layer in a contacting area (110).

Description

[0001] The invention relates to a molded part comprising an electrically conductive functional layer, at least two spaced-apart electrodes connected to the electrically conductive functional layer for supplying electric current into the functional layer, and a component carrier made of plastic material onto which the functional layer is applied.

[0002] Molded parts of the type mentioned above are known and are used, for example, in vehicle seats and interior components of motor vehicles. The electrically conductive functional layer is frequently used as a heating element, for example, for seat heaters or heated armrests that are formed from or comprise such a molded part. Applications of the electrically conductive functional layer are also known, e.g., as an antenna or as a sensor.

[0003] Crimp connectors are typically used to connect and supply electrical current to the functional layer. These connectors link the conductor tracks of the functional layer with at least two corresponding, spaced-apart electrodes. In addition, snap fasteners, conductive adhesives, and spring-loaded connectors are also known as means for connecting and supplying electrical current. For example, EP 2 457 411 B1 discloses an electrically conductive functional layer that uses spring clips to achieve such contact.

[0004] The known contact methods require significant assembly effort and are expensive. Furthermore, their mechanical durability leaves much to be desired.

[0005] The object of the invention is to propose a molded part of the type mentioned above in which a permanent bond between the functional layer and the electrodes can be achieved at low cost and with minimal manufacturing effort. The invention should also allow for the transmission of larger currents of several amperes, such as those commonly used in heating applications. Furthermore, the molded part should be particularly suitable for typical components, especially in the automotive sector, for example, armrests and trim components.

[0006] This problem is solved by the features of the main claim. Further advantageous embodiments are disclosed in the dependent claims. Also disclosed is a vehicle seat component, automotive interior component, furniture component, or component of a sports device with or made from such a molded part.

[0007] It is provided that the electrodes in the molded part according to the invention are integrated into the surface of the component carrier adjacent to the functional layer and are electrically contacted with the functional layer in a contact area. The electrodes can, for example, be designed as metal strips or metal foils and are connected to the current-carrying connecting cables using known methods, such as soldering or crimping.

[0008] According to one aspect of the invention, the electrodes are back-injected or back-foamed into the component carrier during its manufacture. For this purpose, the electrodes are inserted into the appropriate injection molding or foaming tool at the designated position during the production of the molded part according to the invention and then back-injected or back-foamed with the plastic to form the component carrier. The result is an integral component carrier with the electrodes integrated into its surface.

[0009] According to an alternative proposal of the invention, the electrodes are applied to the surface of the previously manufactured component carrier in an adhesive manner, for example by gluing, which also leads to their integration into the component carrier.

[0010] According to a further aspect of the invention, the electrodes can also be integrated into corresponding recesses in the component carrier, either by means of a positive-locking connection or by bonding the electrodes into such a recess using an adhesive. In these cases, the shape of the component carrier is designed such that its surface is equipped with corresponding recesses for receiving the electrodes, which preferably completely fill the respective recess.

[0011] The electrically conductive functional layer can, for example, be a printed functional layer, such as one obtained by printing an electrically conductive paste onto a suitable electrically non-conductive substrate, for example, based on a textile or a plastic film. The electrically conductive functional layer is applied to the component carrier equipped with the electrodes in such a way that the surface of the component carrier intended for the application of the functional layer is covered by the functional layer, whereby in a designated contact area of ​​the functional layer, it is electrically contacted by the electrodes; that is, the contact area of ​​the functional layer rests on the electrodes.

[0012] To improve contact and increase the corrosion resistance of the electrodes, they can be coated with suitable materials or surface-treated, and / or other suitable conductive adhesives or similar contact mediators can be used.

[0013] Preferably, the electrodes are arranged in an area of ​​the component carrier where there is a high surface pressure on the applied electrically conductive functional layer, for example at edge areas or edges of the molded part according to the invention.

[0014] To further improve positioning and surface pressure over the entire product lifespan of the molded part according to the invention, it can also be provided that at least one retaining clip is incorporated in the contact area between the electrodes and the functional film, which penetrates the respective electrode and the functional layer positioned on it and fixes them precisely in position. The retaining clip can, for example, be U-shaped, as is also known from conventional staples.

[0015] According to a further proposal of the invention, the fastening clips are formed from non-conductive or electrically insulated material, or the fastening clips are formed from electrically conductive material, wherein the exposed area of ​​the same is electrically insulated.

[0016] In addition to manufacturing the fastening clips from non-conductive material, such as suitable plastics, they can also be made from conductive material and at least coated or covered on their surface with an electrically insulating material. Furthermore, it is also possible to use fastening clips made of electrically conductive material, which are subsequently covered or bonded with suitable insulation, e.g., using suitable paints or adhesive tapes.

[0017] In a further embodiment of the molded part according to the invention, a cover substrate is applied to the surface of the functional layer facing away from the component carrier. This cover substrate is formed, for example, by a single- or multi-layered synthetic leather, leather, or textile. This cover substrate is applied to the component carrier, overlapping the functional layer, and thus forms the visible surface of the molded part according to the invention. The electrically conductive functional layer is therefore arranged directly beneath the cover substrate, which is advantageous, for example, for heating applications or for the formation of sensors.

[0018] It is also possible that the functional layer is first laminated onto the back of the top substrate and then this entire structure is applied to the component carrier.

[0019] In a further embodiment of the molded part according to the invention, a plastic foam layer is provided between the component carrier and the functional layer outside the contact areas, for example, between the contact areas of the electrodes used, in order to give the molded part, for example, a soft, elastically compliant feel. Such a plastic foam layer can be provided particularly in molded parts that are formed with an additional top substrate on the surface facing away from the component carrier. In this case, the functional layer advantageously extends between the plastic foam layer and the top substrate.

[0020] The molded part according to the invention, as described above, can be manufactured and assembled with only slightly modified effort compared to known molded parts that lack an electrically conductive functional layer. The molded part according to the invention with an electrically conductive functional layer is therefore particularly well suited for industrial production, with very low additional costs, since the metal strips or foils required for forming the electrodes can be produced very inexpensively and then integrated into the usual manufacturing process for producing the molded parts.

[0021] The molded part according to the invention can be used, for example, to manufacture vehicle seat components, automotive interior parts, furniture components, or components of sports equipment. Examples include car seats, add-on parts for car interiors, seats and interior components of aircraft, ships, public transport and public facilities, upholstered furniture, medical equipment such as massage tables, sports equipment, and bicycle or motorcycle seats or handlebars.

[0022] Further details of the molded part according to the invention are explained schematically below with reference to two exemplary embodiments in the drawing. The drawing shows: Figure 1 shows a first embodiment of a molded part according to the invention in cross-section; Figure 2 shows a second embodiment of a molded part according to the invention in cross-section.

[0023] From the Figure 1The structure of a molded part 1 is shown in a schematic cross-sectional view. The molded part 1 comprises a component carrier 10 designed like an inner core, which is enveloped along a large part of its outer surface by an electrically conductive functional layer 11. This layer is applied to the corresponding surface of the component carrier 10 and has conductive traces (not shown in detail) that, for example, conduct electricity when an electric current is applied to the layer, thus giving the functional layer 11 the function of a heater when it heats up as a result of the current flowing through the conductive traces. A typical application example is a heated armrest in a motor vehicle.

[0024] To supply the electric current into the functional layer 11, two electrodes 12 spaced apart from each other are provided, arranged on opposite sides of the component carrier 10, which are made, for example, of suitable metal strips and are connected to connecting lines in a manner not shown, for example by soldering.

[0025] The electrodes 12 are integrated into corresponding recesses 100 of the component carrier 10 and completely fill them. Such integration of the electrodes 12 into the component carrier 10 can be achieved, for example, by inserting the electrodes 12 into the injection mold used during the plastic injection molding process for the component carrier 10 and then overmolding them with the plastic material to form the component carrier 10. The result is a component carrier 10 with integrated electrodes 12.

[0026] The electrically conductive functional layer 11 is then applied to the component carrier 10, which is provided with the electrodes 12, as shown. The functional layer 11 comes into contact with the electrodes 12 in a designated contact area 110 and is thus electrically connected. Additionally, at least one U-shaped retaining clip 13, for example made of an electrically non-conductive plastic material, can be inserted through the functional layer 11 and the electrode into the component carrier 10 in the contact area 110 to permanently secure the position of the functional layer 11 relative to the electrodes and their contact.

[0027] In the exemplary embodiment according to Figure 2 is a difference from the embodiment in Figure 1A modified embodiment of such a molded part 1 is evident, in which the same parts have been given the same reference numerals and are not explained again to avoid repetition.

[0028] However, it can be seen that in addition to the embodiment according to Figure 1 an electrically conductive functional layer 11 applied to the component carrier 10, a top substrate 14 forming the visible side, for example a single or multi-layer artificial leather, is applied, which covers the surface of the functional layer 11 facing away from the component carrier 10, so that the functional layer 11 lies directly under the top substrate 14.

[0029] Furthermore, a plastic foam layer 15 can be provided in certain areas between the component carrier 10 and the functional layer 11 outside the contact areas 110, i.e., between the two electrodes 12. This layer can be, for example, inserted into a corresponding recess in the component carrier 10, thus positioning it between the component carrier 10 and the electrically conductive functional layer 11. The plastic foam layer 15 can be attached to the component carrier 10 and / or the functional layer 11, for example, by adhesive bonding. This plastic foam layer 15 imparts an elastic flexibility to the molded part, which is particularly desirable, for example, when used as an armrest.

[0030] In this configuration as well, the electrically conductive functional layer runs directly beneath the top substrate 14 and can, for example when used as a heating element, optimally transfer its heating energy to the surface of the top substrate 14. Reference symbol list:

[0031] 1 Molded part 10 Component carrier 11 Functional layer 12 Electrode 13 Mounting clip 14 Top substrate 15 Plastic foam layer 100 Recess 110 Contact area

Claims

1. Molded part (1) comprising an electrically conductive functional layer (11), at least two spaced-apart electrodes (12) connected to the electrically conductive functional layer (11) for supplying electric current into the functional layer (11) and a component carrier (10) made of plastic material onto which the functional layer (11) is applied, characterized by the fact that the electrodes (12) are integrated into the surface of the component carrier (10) adjacent to the functional layer (11) and are electrically contacted with the functional layer in a contacting area (110).

2. Molded part (1) according to claim 1, characterized by the fact that the electrodes (12) are back-injected or back-foamed from the component carrier (10).

3. Molded part (1) according to claim 1, characterized by the fact that the electrodes (12) are firmly attached to the surface of the component carrier (10).

4. Molded part (1) according to one of claims 1 to 3, characterized by the fact thatthe electrodes (12) are arranged in corresponding recesses (100) of the component carrier (10).

5. Molded part (1) according to one of claims 1 to 4, characterized by the fact that In the contacting area (110) between electrodes (12) and functional foil (11) at least one fastening clip (13) is inserted into the functional layer (11) and the electrode (12).

6. Molded part (1) according to claim 5, characterized by the fact that the fastening clip (13) is made of non-conductive or electrically insulated material, or the fastening clip (13) is made of electrically conductive material, wherein the exposed area of ​​the fastening clip (13) is electrically insulated.

7. Molded part (1) according to any one of claims 1 to 6, characterized by the fact that A top substrate (14) is applied to the surface of the functional layer (11) facing away from the component carrier.

8. Molded part (1) according to one of claims 1 to 7, characterized by the fact thatA plastic foam layer (15) is provided between the component carrier (10) and the functional layer (11) outside the contact areas (110) of the same.

9. Vehicle seat component, automotive interior component, furniture component or component of a sports device comprising or consisting of a molded part (1) according to any of the preceding claims.