Molded Product Standing Wall FPC Embedding
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Solution Overview
Problem
The integration of a functional circuit and external connecting portion in molded products, such as those with touch sensors, often results in aesthetic challenges and frequent disconnection issues during the manufacturing process due to pressure applied during injection molding.
Innovation Solution
A molded product design that includes a resin main body with a standing wall, a decorative sheet with a conductive circuit layer, and a flexible printed circuit board (FPC) embedded into the standing wall, where the FPC is electrically connected to the conductive circuit layer using an anisotropic conductive film, and the decorative sheet is integrated with the molded article to enhance aesthetics and prevent disconnection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the functional circuit and external connecting portion are integrated in a decorative sheet, then integration with the molded article is achieved, but preforming becomes difficult and aesthetic appearance deteriorates
Solution Approach 1:
The patent divides the external connecting portion from the decorative sheet by introducing a standing wall structure. The flexible printed circuit board is placed in a groove formed on the standing wall, separating the connection function from the decorative function. This segmentation allows the decorative sheet to be preformed independently while maintaining integration reliability through the groove structure.
Solution Approach 2:
The standing wall acts as an intermediary structure between the decorative sheet and the flexible printed circuit board. The groove on the standing wall provides a dedicated space for the FPC, mediating the connection between the decorative component and the electrical component without compromising either the aesthetic appearance or the integration reliability.
2Reliability
If pressure is applied during injection molding to integrate components, then integration is achieved, but disconnection between functional circuit and external connecting portion occurs
Solution Approach 1:
The flexible printed circuit board is nested within the groove formed on the standing wall. This nesting structure protects the FPC from direct pressure during injection molding while maintaining its electrical connection to the decorative sheet. The groove acts as a protective cavity that prevents disconnection under pressure.
Solution Approach 2:
The groove structure is pre-formed on the standing wall before injection molding to provide preliminary protection against pressure-induced disconnection. This preliminary structural arrangement counteracts the harmful effects of injection pressure before the molding process begins, preventing the FPC from disconnecting during manufacturing.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution provides an aesthetically pleasing appearance and reduces the likelihood of disconnection between the FPC and the conductive circuit layer, ensuring a stable and functional electrical product.
Implementation Method 1
electrically connected to the conductive circuit layer using an anisotropic conductive film
Data Source
AI summary
A molded product and an electrical product comprising a molded article that includes a main body made of resin and a standing wall made of resin. The standing wall integrally stands up from the end portion of the main body. A decorative sheet includes a base film and a conductive circuit layer. The base film continuously covers from the main body front surface to a wall front surface. The conductive circuit layer is disposed between the base film and the main body front surface. The decorative sheet is integrated with the molded article to implement a decoration with the base film. A flexible printed circuit board is disposed between the molded article and the conductive circuit layer. The flexible printed circuit board is partially embedded into and integrated with the standing wall. The flexible printed circuit board is electrically connected to the conductive circuit layer.