In-mold electronics within a robotic device

A robotic device having in-mold electronics is provided. According to one or more aspects, a robotic device includes an electronic computing unit for controlling the robotic device and a molded part. The molded part includes a thermoformed first film, structural layer, electronic circuit, and a functional component. The molded structural layer is arranged under the first film. The thermoformed second film arranged under the structural layer. The electronic circuit arranged over the second film and adjacent the structural layer. The electronic circuit includes a functional component communicably coupled to the electronic computing unit. The first film is arranged to cover the structural layer, the second film, and the electronic circuit to define an exposed surface of the molded part.

BACKGROUND

Molded parts are used as for robotic devices. However, these molded parts often do not have any functionality. To impart functionality to the molded parts, a functional component may be affixed to a molded part. The molded part may require a rather complex structure for accommodating the functional component so as to conceal the functional component from view and protect it from impact. The complexity of the structures can be further exacerbated by environmental factors that the functional component is exposed to. The complex structure for affixing the functional component to the robotic device may include a number of components to that provide waterproofing for the functional component against moisture such as rain, fog, dew, etc. The complex structure may also protect the functional component from other aspects of the environment of the robotic device, such as the terrain. However, these structures may add weight and bulk to the robotic devices.

BRIEF DESCRIPTION

According to one aspect, a robotic device including an electronic computing unit for controlling the robotic device and a molded part. The molded part includes a thermoformed first film, structural layer, electronic circuit, and a functional component. The molded structural layer is arranged under the first film. The thermoformed second film arranged under the structural layer. The electronic circuit arranged over the second film and adjacent the structural layer. The electronic circuit includes a functional component communicably coupled to the electronic computing unit. The first film is arranged to cover the structural layer, the second film, and the electronic circuit to define an exposed surface of the molded part.

According to one aspect, a robotic device including an electronic computing unit for controlling the robotic device and a molded part. The electronic computing unit includes a processor for processing sensor data from at least one functional component. The molded part includes a thermoformed first film, structural layer, electronic circuit, and a functional component. The molded structural layer is arranged under the first film. The thermoformed second film arranged under the structural layer. The electronic circuit arranged over the second film and adjacent the structural layer. The electronic circuit includes the at least one functional component communicably coupled to the electronic computing unit. The first film is arranged to cover the structural layer, the second film, and the electronic circuit to define an exposed surface of the molded part.

According to another aspect, method of producing a molded part of a robotic device includes providing a first thermoformable film and a thermoformed second film. The method further includes arranging a plurality of functional components on the second film. In some embodiments, a structural layer may be arranged between the first thermoformable film and the plurality of functional components. The method further includes arranging the first thermoformable film, the plurality of functional components, and the thermoformed second film. The method also includes injecting resin into the mold to form an exposed surface of the robotic device.

DETAILED DESCRIPTION

As discussed above, adding functional components to robotic devices can add size, weight, and moving parts to robotic devices, which can make the robotic devices unwieldly and fragile. Generally, the systems and method disclosed herein are directed to a robotic device having a molded part with an in-mold functional component. By using in-mold functional components, the robotic device does not suffer the additional weight and bulk of structures used to affix functional components to the molded part of the robotic device. Accordingly, the functional components may be formed with the molded part of the robotic device such that the functional parts are embedded within the robotic device. For example, the functional components may be formed with the molded part of the robotic device using injection molding techniques. In addition to not requiring unwieldly structures for affixing the functional components, the functional parts are protected due to the functional components being formed with the molded part and thus embedded in the robotic device. Accordingly, additional components are not required to waterproof, protect, etc. the functional components. Furthermore, because the functional components are in-molded, the robotic device has fewer moving parts. Thus, the robotic devices can be utilized for more difficult operations and/or be used in more hostile environments.

Definitions

The following includes definitions of selected terms employed herein. The definitions include various examples and/or forms of components that fall within the scope of a term and that can be used for implementation. The examples are not intended to be limiting.

A “bus,” as used herein, refers to an interconnected architecture that is operably connected to other computer components inside a computer or between computers. The bus can transfer data between the computer components. The bus can be a memory bus, a memory controller, a peripheral bus, an external bus, a crossbar switch, and/or a local bus, among others. The bus can also be a vehicle bus that interconnects components inside a vehicle using protocols such as Media Oriented Systems Transport (MOST), Controller Area network (CAN), Local Interconnect Network (LIN), among others.

“Computer-readable medium,” as used herein, refers to a non-transitory medium that stores instructions and/or data. A computer-readable medium can take forms, including, but not limited to, non-volatile media, and volatile media. Non-volatile media can include, for example, optical disks, magnetic disks, and so on. Volatile media can include, for example, semiconductor memories, dynamic memory, and so on. Common forms of a computer-readable medium can include, but are not limited to, a floppy disk, a flexible disk, a hard disk, a magnetic tape, other magnetic medium, an ASIC, a CD, other optical medium, a RAM, a ROM, a memory chip or card, a memory stick, and other media from which a computer, a processor or other robotic device can read.

A “database,” as used herein can refer to table, a set of tables, a set of data stores and/or methods for accessing and/or manipulating those data stores. Some databases can be incorporated with a disk as defined above.

A “device system,” as used herein can include, but is not limited to, any automatic or manual systems that can be used to enhance the mobility, planning, and/or safety. Exemplary device systems include, but are not limited to: an electronic stability control system, boundary monitoring system, an anti-lock brake system, a brake assist system, an automatic brake prefill system, a low speed follow system, a cruise control system, a collision warning system, a collision mitigation braking system, an auto cruise control system, a lane departure warning system, a blind spot indicator system, a lane keep assist system, a navigation system, a transmission system, brake pedal systems, an electronic power steering system, visual devices (e.g., camera systems, proximity sensor systems), a climate control system, an electronic pretensioning system, a monitoring system, a passenger detection system, a vehicle suspension system, a vehicle seat configuration system, a vehicle cabin lighting system, an audio system, a sensory system, among others.

A “disk,” as used herein can be, for example, a magnetic disk drive, a solid state disk drive, a floppy disk drive, a tape drive, a Zip drive, a flash memory card, and/or a memory stick. Furthermore, the disk can be a CD-ROM (compact disk ROM), a CD recordable drive (CD-R drive), a CD rewritable drive (CD-RW drive), and/or a digital video ROM drive (DVD ROM). The disk can store an operating system that controls or allocates resources of a computing device.

“Logic circuitry,” as used herein, includes, but is not limited to, hardware, firmware, a non-transitory computer readable medium that stores instructions, instructions in execution on a machine, and/or to cause (e.g., execute) an action(s) from another logic circuitry, module, method and/or system. Logic circuitry can include and/or be a part of a processor controlled by an algorithm, a discrete logic (e.g., ASIC), an analog circuit, a digital circuit, a programmed logic device, a memory device containing instructions, and so on. Logic can include one or more gates, combinations of gates, or other circuit components. Where multiple logics are described, it can be possible to incorporate the multiple logics into one physical logic. Similarly, where a single logic is described, it can be possible to distribute that single logic between multiple physical logics.

A “memory,” as used herein can include volatile memory and/or non-volatile memory. Non-volatile memory can include, for example, ROM (read only memory), PROM (programmable read only memory), EPROM (erasable PROM), and EEPROM (electrically erasable PROM). Volatile memory can include, for example, RAM (random access memory), synchronous RAM (SRAM), dynamic RAM (DRAM), synchronous DRAM (SDRAM), double data rate SDRAM (DDR SDRAM), and direct RAM bus RAM (DRRAM). The memory can store an operating system that controls or allocates resources of a computing device.

A “module,” as used herein, includes, but is not limited to, non-transitory computer readable medium that stores instructions, instructions in execution on a machine, hardware, firmware, software in execution on a machine, and/or combinations of each to perform a function(s) or an action(s), and/or to cause a function or action from another module, method, and/or system. A module may also include logic, a software controlled microprocessor, a discrete logic circuit, an analog circuit, a digital circuit, a programmed logic device, a memory device containing executing instructions, logic gates, a combination of gates, and/or other circuit components. Multiple modules may be combined into one module and single modules may be distributed among multiple modules.

An “operable connection,” or a connection by which entities are “operably connected,” is one in which signals, physical communications, and/or logical communications can be sent and/or received. An operable connection can include a wireless interface (e.g., for wireless charging), a physical interface, a data interface, and/or an electrical interface.

A “portable device,” as used herein, is a computing device typically having a display screen with user input (e.g., touch, keyboard) and a processor for computing. Portable devices include, but are not limited to, handheld devices, mobile devices, smart phones, laptops, tablets, e-readers, smart speakers. In some embodiments, a “portable device” could refer to a remote device that includes a processor for computing and/or a communication interface for receiving and transmitting data remotely.

A “processor,” as used herein, processes signals and performs general computing and arithmetic functions. Signals processed by the processor can include digital signals, data signals, computer instructions, processor instructions, messages, a bit, a bit stream, or other means that can be received, transmitted and/or detected. Generally, the processor can be a variety of various processors including multiple single and multicore processors and co-processors and other multiple single and multicore processor and co-processor architectures. The processor can include various modules to execute various functions.

“Robotic device,” as used herein, is any electronic device capable of some degree of autonomous mobility. Exemplary robotic devices can include, but are not limited to self-propelled lawn mowers, self-propelled vacuum cleaners, manual self-propelled wheelchairs, powered wheelchairs, scooters, bicycles, carts, and strollers. The robotic device may also be a vehicle capable of carrying one or more human occupants, cargo, conveyance device, etc., powered by any form of energy. In some embodiments, the robotic device can include various sensors for sensing and determining various parameters of the environment. For example, location, weather conditions, and travel parameters, among others. Some robotic devices have user input and output functionality.

“Value” and “level”, as used herein can include, but is not limited to, a numerical or other kind of value or level such as a percentage, a non-numerical value, a discrete state, a discrete value, a continuous value, among others. The term “value of X” or “level of X” as used throughout this detailed description and in the claims refers to any numerical or other kind of value for distinguishing between two or more states of X. For example, in some cases, the value or level of X may be given as a percentage between 0% and 100%. In other cases, the value or level of X could be a value in the range between 1 and 10. In still other cases, the value or level of X may not be a numerical value, but could be associated with a given discrete state, such as “not X”, “slightly x”, “x”, “very x” and “extremely x”.

System Overview

Referring now to the drawings, wherein the showings are for purposes of illustrating one or more exemplary embodiments and not for purposes of limiting same,FIGS. 1 and 2illustrate a robotic device2having in-mold functional components. The robotic device2includes a molded part4and an electronic computing unit6. The molded part4includes a first film8, a molded polymeric structural layer10, and an in-molded printed electronic circuit12. The molded part4optionally includes second film14and graphics16on an exposed surface18of the robotic device2.

The first film8and the second film14may each be thermoformable, and may include the same or different materials. The first film8and the second film14may each include a flat thin-gauged thermoplastic polymer sheet that can be heated to a pliable forming temperature, formed to a specific shape (e.g. in a mold), and cooled to retain the specific shape. The first film8and the second film14may each include acrylic, acrylonitrile butadiene styrene, nylon, polylactic acid, polybenzimidazoles, polycarbonate, polysulfone, polyoxymethylene, polyetherether ketone, polyetherimides, polyvinyl chloride, polyethylene, polyphenylene oxide, polyphenylene sulfide, polypropylene, polystyrene, polytetrafluoroethylene, other thermoplastics, or combinations thereof. Before being thermoformed, the first film8and the second film14, may each have a gauge of less than 1.5 mm. At these gauges, the first film8and the second film14are not considered structural films in that they may not support their own shape or the shape of the molded part4before or after thermoforming, and instead may bend or otherwise deform when unsupported by the structural layer10.

The first film8is arranged to cover the other components of the molded part4(including the circuit12), and may therefore define an exposed surface18of the molded part4and the robotic device2. The exposed surface18may be the outermost surface of the robotic device2that is most visible while the non-exposed surface20is not generally visible. For example, suppose that the robotic device2is a robotic lawnmower. The exposed surface18may be visible during mowing operations while blades (not shown) may cut grass through an opening in the non-exposed surface20.

The first film8may act as a substrate upon which the electronic circuit12is printed as shown inFIGS. 2-4. The first film8may be initially flat, and then be made contoured as a result of being thermoformed/molded. As seen inFIGS. 1 and 2, the first film8may include viewing features22that allow viewing through the first film8from the exposed surface18. Such viewing features22may be apertures, thinned areas, or other features in the first film8that allows viewing through the first film8.

If the second film14is included in the robotic device2, the second film14may be arranged under the other components of the molded part4, and may define a non-exposed surface20of the molded part4that is on a side of the molded part4opposite from the exposed surface18. The non-exposed surface20may be the innermost surface of the of the molded part4that is least visible or not visible at all when the robotic device2is included as a component of the vehicle. The second film14may be provided as a substrate upon which the electronic circuit12is printed. If the second film14is not included in the molded part4, the first film8may act as a substrate upon which the electronic circuit12is printed. The second film14may be initially flat, and then be made contoured as a result of thermoforming/molding.

The structural layer10is provided as a structural support for the other components of the molded part4and robotic device2, in order to maintain a shape of the robotic device2. The structural layer10is arranged under, and is covered by, the first film8, and may be arranged over, and thus covering, the second film14if included. The structural layer10is arranged adjacent to, and may contact, the circuit12. InFIGS. 2 and 4, the structural layer10is arranged over the circuit12and second film14, and as such, the structural layer10may be transparent.

InFIG. 5, the structural layer10is arranged under the circuit12and no second film14is included. The structural layer10may have a thickness of more than 3 mm in order to provide structural support for the molded part4. At these thicknesses, the structural layer10may be able maintain its own shape, even if not supported by other components or material, and may be able maintain the shape of the other components of the robotic device2.

The structural layer10may include a molded polymer that is formed by curing a resin material. The polymer may include a variety of thermoplastics, thermosets, or combinations thereof. The structural layer10may include other materials such as fillers, reinforcements (e.g. fibers of glass or aramid), other additional layers, etc., or combinations thereof. In a non-limiting embodiment, the structural layer10includes a thermoplastic polymer that is cured by cooling a molten resin material. The structural layer10may be coextensive with the first film8and/or the second film14.

The electronic circuit12is included to provide functionality to the robotic device2. The circuit includes one or more flexible conductive traces24, a communications antenna26electrically connected to the traces24, and one or more light sources28electrically connected to the traces24. Although the circuit12is depicted in the figures as being a continuous layer, this is only for convenience in order to show the arrangement of the various elements of the molded part4, and it will be understood that the circuit12may or may not comprise voids between conductive traces24, the communications antenna26, and the light sources28, and therefore the circuit12may or may not be a continuous layer as depicted.

The circuit12may be printed on the top surface30of the second film14or on a bottom surface32of the first film8. The circuit12includes the functional components such as the conductive traces24, the communications antenna26, the light sources28, and the sensor36. The circuit12may be flexible and therefore may conform to the contours of the thermoformed first film8and the second film14. By “flexible”, it is meant a layer, circuit, trace or other element or material that is not rigid, brittle, or stiff, and instead bends, stretches, changes shape, or otherwise yields to external forces, yet does not break or lose functionality when subject to such external forces. When referring to the “flexible electronic circuit,” the electronic circuit12does not break and retains its conductivity even when bent, stretched, twisted or otherwise deformed to a strain of 1% to at least 35%.

In one embodiment, the molded part4includes only one electronic circuit12. In another embodiment, the molded part4includes more than one electronic circuit12, for example, two, three or more electronic circuits12. When more than one circuit12is included in the molded part4, each circuit12may be configured to perform a different function than the other circuits12, which may mean that each circuit12is electrically isolated/separated from the other circuits12, or the circuits12can be independently operated, or each circuit12can function separately from the other circuits12, or the circuits12are electrically connected to different types of functional elements. The functional elements may be printed on the circuits in a single layer and/or on a single film.

As depicted inFIG. 6, the circuit12may formed with application of a graphic ink layer48, a conductive ink layer50, a dielectric ink layer52, a conductive adhesive layer54, and the light sources28. The graphic ink layer48may be included to provide a desired visual appearance to the robotic device2, for example, a part of the circuit12that may be visible through the viewing features22. The conductive ink layer50may be used to form the conductive traces24. The dielectric ink layer52may be used to insulate the conductive traces24. The conductive adhesive layer54may be used to adhere and electrically connect various functional components to the conductive traces24, such as communications antenna26, light sources28, or other pick-and-place surface mounted electronic elements that are not printed electronic elements, for example. The circuit12includes a communications antenna26and a printed circuit board (PCB)34, both of which may be flexible. The communications antenna26may be communicably coupled to the electronic computing unit6.

Turning toFIG. 7, the electronic computing unit6of the robotic device2with provisions for processing, communicating, and interacting with various components of the robotic device2. The components and functions of the electronic computing unit6can be implemented remotely from the robotic device2, for example, with a portable device or another device connected via a network (not shown).

Generally, the electronic computing unit6includes a processor104, a memory106, a disk108, and an input/output (I/O) interface110, which are each operably connected for computer communication via a bus112and/or other wired and wireless technologies. The I/O interface110provides software and hardware to facilitate data input and output between the components of the electronic computing unit6and other components, networks, and data sources, which will be described herein. Additionally, the processor104may include modules and/or logic circuitry for operating the robotic device2.

The electronic computing unit6is also operably connected for computer communication (e.g., via the bus112and/or the I/O interface110) to one or more functional components114such the conductive traces24, such as communications antenna26, light source28, the sensor36or other pick-and-place surface mounted electronic elements that are not printed electronic elements, for example. The electronic computing unit6may also be operably connected to device systems116can include, but are not limited to, any automatic or manual systems that can be used to enhance the robotic device2, driving, and/or safety. The functional components114and/or the from which this data or these signals are derived, or to which this data or these signals are communicated, are not particularly limited and may include one or more vehicle electronic computing units (ECU's) associated with the robotic device2. The device systems116can include a door control unit, engine control unit, electric power steering control unit, human-machine interface (HMI), powertrain control module, transmission control unit; seat control unit, speed control unit, telematics control unit, transmission control unit, brake control module (ABS or ESC), battery management system, central control module, central timing module, general electronic module, body control module, suspension control module, or combinations thereof.

As discussed above, the device systems116include and/or are operably connected for computer communication to the functional components114. The functional components114provide and/or sense information associated with the robotic device2, the environment, the device systems116, etc. The functional components114can include, but are not limited to, environmental sensors, speed sensors, brake sensors, throttle position sensors, wheel sensors, anti-lock brake sensors, among others. In some embodiments, the functional components114are incorporated with the device systems116. For example, the functional components114may include external cameras, radar and laser sensors to detect the presence of an object. Additionally, the functional components114may detect characteristics of the object, such as location and speed of the object, as well as relative characteristics of the robotic device2and the object, such as relative distance and speed between the robotic device2and the object.

Accordingly, the functional components114are operable to sense a measurement of data associated with the robotic device2, the vehicle environment, and the device systems116, and generate a data signal indicating said measurement of data. These data signals can be converted into other data formats (e.g., numerical value) and/or used by the device systems116and/or the electronic computing unit6to generate other data metrics, values, and/or parameters. It is understood that the functional components114can be any type of sensor, for example, acoustic, electric, environmental, optical, imaging, light, pressure, force, thermal, temperature, proximity, among others.

The functional components114may additionally or alternatively include a light source, sensor, auxiliary power sources, capacitors, inductors, diodes, resistors, transformers, switches, other electrical loads, fuses, antennas, wireless transmitters, heaters, etc., each of which may be flexible. The functional components may also include a light source, sensor, auxiliary power sources, capacitors, inductors, diodes, resistors, transformers, switches, other electrical loads, fuses, antennas, wireless transmitters, heaters, etc., each of which may be flexible. However, it will be understood that these or other light sources28may be included in electrical communication with the circuits12, but arranged elsewhere other than as part of the circuit12. The light sources28may be a micro light emitting diode. The functional components114may be arranged in any possible configuration of the one or more electronic circuits12.

The one or more electronic circuits12(including one or more conductive traces24, the communications antenna26, the light sources28, and a capacitive sensor42) may be formed using an electrically conductive ink that includes a binder (e.g. polymer material such as polyimide) and conductive particles, including for example, copper, ferromagnetic material, silver, carbon, silver chloride, or other electrically conductive particles. The one or more electronic circuits12may be formed by applying, e.g. printing, a conductive ink directly on the first film8and/or the second film14, followed by curing, drying, hardening, etc. of the conductive ink. For example this method may be used to form the conductive traces24, the communications antenna26, the light sources28, and a capacitive sensor42of the one or more electronic circuits12. The conductive traces24, the communications antenna26, the light sources28, and a capacitive sensor42may be defined by or include a printed and cured conductive ink. Numerous conductive inks are suitable to create the one or more electronic circuits12and/or the functional components114, and may include, for example, Stretchable Conductors, Ink-Jet Silver Conductor, Ag Conductors, Stretchable Silver Conductors, and Ultra-Low Temperature Cure Silver Composite Conductors, among others.

These conductive inks can be applied on the first film8and/or second film14by any method including pad-printing, flexography, rotogravure, spraying, dipping, syringe dispensing, stenciling, screen printing, aerosol jet printing, or inkjet printing for example in order to create an electronic circuit. The flexible electronic circuits12can be formed using other materials or processes including etching, in-mold forming of the one or more electronic circuits12, selective photocuring, and circuit scribe, for example. In one illustrative embodiment, the one or more electronic circuits12are formed by screen printing a conductive ink on the first film8and/or the second film14based on the arrangement of the functional elements. The conductive inks are applied on the first film8and/or second film14based on the arrangement of the functional components114.

In an embodiment, graphics16may be arranged over the first film8on the exposed surface18of the robotic device2so as to be visible from the exposed surface18. Although the graphics16are depicted inFIGS. 2-4as being a continuous layer, this is simply for convenience, and it should be understood that the graphics16may or may not be a continuous layer. The graphics16and/or the first film8, may at least partially conceal or camouflage the circuit12including the flexible conductive traces24, the communications antenna26, the light sources28, and the PCB34. The graphics16and/or the first film8may also conceal or camouflage the structural layer10and the second film14. The graphics16are not particularly limited by the present subject matter, and may include a translucent or opaque layer, film, ink, or coating arranged over the flexible circuit12. By “translucent” it is meant a material or layer that allows light to pass therethrough, but causes sufficient diffusion to prevent perception of distinct images through the material or layer. In another embodiment, the graphics16are not included, or the graphics16are clear (i.e. optically transparent) and/or the circuit12and light sources28thereof are positioned on top of the graphics16.

In a non-limiting example, the graphics16and/or the first film8produce sufficient diffusion of light such that visibility through the graphics16and or first film8, of the flexible electronic circuit12and all the light sources28of the circuit12, except for light (L) emitted by the light source28, is inhibited by the graphics16and/or first film8. In one embodiment, the flexible electronic circuit12and all the light sources28of the circuit12may not be visible through the graphics16and/or first film8. The light source28is also under the graphics16and the first film8, and therefore visibility of the light source28through the graphics16and/or first film8may be inhibited by the graphics16and/or first film8. In one embodiment, the light source28may not be visible through the graphics16and/or first film8. However, the graphics16and/or first film8are sufficiently translucent (rather than being opaque) such that light emitted by the light source28is visible through the graphics16and/or first film8. Accordingly, the graphics16and/or first film8at least in some measure conceals the flexible circuit12(including the light source28) from view, yet allows light (L) emitted from the light source28to be transmitted therethrough so that the emitted light is visible through the graphics16and the first film8. Light (L) emitted from the light source28that is transmitted through the graphics16and/or first film8may be used for illumination or as a visual indicator to convey information.

In one embodiment, the first film8includes viewing features22that allow viewing of the emitted light (L) from the light source28. Such viewing features22may be arranged above the light source28to allow the emitted light (L) to be seen from the exposed surface18. The first film8may be transparent, and thus allows emitted light (L) to be transmitted therethrough. In this aspect, the graphics16may not cover areas of the first film8above the light source28to thereby define the viewing features22and allow emitted light (L) to be seen from the exposed surface18through the viewing features22.

The graphics16may be an ink, polymer, textile, composite material, enamel, paper, glass, metal, ceramic, other material, and combinations thereof. In one non-limiting example, the graphics16comprises a pigmented ink including for example a mixture of polymer and pigment particles. The polymer may be an acrylic urethane resin for example. The graphics16may be formed by applying the ink as a liquid over the first film8and curing the polymer in the ink to produce the graphics16. The graphics16may have a pigment loading and/or thickness sufficient to inhibit or prevent the circuit12from being visible through the graphics16. However, the graphics16may be sufficiently translucent, as opposed to being opaque, such that light (L) emitted by the light source28can be seen through the graphics16. In one non-limiting embodiment, the graphics16have a thickness on the first film8from 5-50 μm, 15-40 μm, or 20-30 μm.

Operation of the robotic device2, the electronic circuits12, and the associated light sources28, may correspond to signals or data derived from one or more of the device systems116of the robotic device2or may be continuously activated during operation of the robotic device2. The data or signals may be accessed from, sensed by, generated by, or otherwise acquired from, or produced by, one or more of the vehicle electronic systems.

In an embodiment, the molded part4may include the printed circuit board (“PCB”)34for controlling the supply of electric current from the communications antenna26to the light sources28via the conductive traces24. The PCB34may be programed or may communicate via a wireless transmitter with the one or more electronic systems of the vehicle, which communication may be for determining when to provide electrical current to, and thus activate, the various light sources28. The PCB34may also include a rectifier to convert alternating current from the communications antenna26to direct current delivered to the various light sources28.

Further, the robotic device2, the electronic circuits12, and the associated light sources28, may provide signals or data to the one or more electronic systems of the vehicle via the PCB34. For example and as described in more detail herein, the robotic device2may include a sensor36and signals from the sensor36may be communicated to the vehicle electronic systems via the PCB34, and these signals may be used to operate other light sources28in the robotic device2or to operate various operations of the vehicle. The sensor36is not particularly limited, and can include a sensor having any configuration including those that can sense pressure, movement, temperature, proximity, location, speed, velocity, acceleration, tilt, motion, humidity, ambient light, etc.

In another non-limiting example, the one or more electronic circuits12are in communication, via the PCB34, with a human machine interface (HMI), which may be used to control functioning of the robotic device2, the electronic circuits12, and the associated light sources28. Such arrangement could allow a user to provide input through the HMI to selectively activate the electronic circuits12and associated light sources28. Such user input may be active (user initiated) or passive (sensed input from a user), and can include audible or tactile input. For example, the system may be configured to allow a user to audibly select operation of the robotic device2, the electronic circuits12, and the associated functional components114.

For example, suppose that the robotic device2is a robotic lawn mower. The viewing features22may allow the light sources28to be visible though the first film8. The light sources28may be arranged in relation to another electronic element, such as a sensor, so that light (L) emitted by the light sources28indicate a location and/or functioning of the robotic device2. For example, the light sources28may be arranged in a U-shape44in a top view that includes a first longitudinal portion62, a center portion64, and a second longitudinal portion66that transition continuously without interruption. The first longitudinal portion62and the second longitudinal portion66extend in a longitudinal direction of the robotic device2in a top view.

The center portion64extends in a transverse direction of the robotic device2in a top view. The light sources28of the center portion64may be a portion of a detection system38. Alternatively, light sources40of the detection system38may be separate from the light sources28such that the detection system38is flanked by the U-shape44. In another embodiment, the center portion64may extend in a longitudinal direction to, at least partially, cover the detection system38. The light sources40are similarly formed as function components114in the manner described above. The light sources40emit light through viewing features22of the first film8. The detection system38may also include the capacitive sensor42. The capacitive sensor42is configured to detect obstacles in the path of the robotic device2. The device systems116may alter the path of the robotic device2based on the detection of the capacitive sensor42.

In one embodiment, the first longitudinal portion62indicates an amount of battery power that the robotic lawn mower has left. For example, the viewing features22and/or light sources28may have a high portion56that is colored such that green light is emitted, a mid-portion58that is colored such that yellow light is emitted, a low portion60that is colored such that red light is emitted. The portion and/or the light sources28may be illuminated based on a power management system118the device systems116. Accordingly, the processor104may send and receive data from the power management system118, to cause a change to the first longitudinal portion62. For example, the high portion56may be delluminated and the mid-portion58may be illuminated in response to data from the power management system118. For example, the processor104may receive information about power management from the power management system118and effect a change to the functional components114of the robotic device2.

The light sources28of the center portion64may also/alternatively emit light (L) to indicate that the sensor36has detected motion. Such detected motion may cause the sensor36to generate a signal, which can be transmitted to a vehicle system via a wireless communication transmitter in the printed circuit12, in order to actuate the opening or closing of a door of the vehicle, or other function. In this manner, the functional components114may be actuated by the electronic control unit102based on information from the device systems116including one or more sensors.

The light sources28of the second longitudinal portion66may indicate a different operational status of the robotic device than the first longitudinal portion62and the center portion64. The light sources28may illuminate differently based on the operational status. For example, the second longitudinal portion66may be illuminated continuously to indicate that the robotic device2is functioning properly, whereas the second longitudinal portion66may be illuminated in a flashing manner to indicate that the robotic device2requires maintenance. The pattern of the flashing may indicate different statuses, such as different forms of maintenance that are required. Additionally or alternatively, the light sources may change color or illuminate different portions of the second longitudinal portion66as described above with respect to the first longitudinal portion62.

The center portion64may extend in a longitudinal direction to, at least partially, cover the detection system38. The communications antenna26may be arranged adjacent a free end of the first longitudinal portion62and or the second longitudinal portion66. The location of the communication antenna26may be demarcated by graphics16.

Continuing the example from above and the robotic device2may be a robotic lawn mower. The device systems116may include a mowing module that includes a number of mowing pattern. The sensor36may monitor the progress of the robotic device2over the terrain. In one embodiment, the communications antenna26may communicate the progress of the robotic device2to a portable device (not shown). Accordingly, the functional components114are used to improve the functionality of the robotic device2, and because the functional components114are in-molded, they improve the operation of the robotic device as the in-molded functional components114reduce the bulk, size, and number of moving parts of the robotic device2.

FIG. 8is a process flow diagram of a method200for producing a molded part having in-molded functional components114for a robotic device according to an exemplary embodiment. At block202, the molded part4may be prepared by performing steps including providing a film, such as the first film8and/or the second film14. At block204, the method includes arranging a plurality of functional components114on the first film8and/or the second film14. For example, the functional components114may be printed on the electronic circuit12, including the communications antenna26, on the first film8and/or the second film14. The circuit12may be printed on the surface of the first film8and/or the second film14or otherwise applied to the first film8and/or the second film14. In one aspect, the circuit12is printed on the film using a conductive ink. The film and the circuit12are then arranged in a mold to undergo a molding process to form the molded part4.

At block206, the method200include arranging the film (e.g., the first film8and/or the second film14) and the functional components in a mold. If the circuit12is arranged on the first film8(FIGS. 3-4), then use of the second film14is not necessary to produce the molded part4since the first film8will support the circuit12during the molding process. However, if the second film14is being included in the molded part4, then the second film14may also be arranged in the mold along with the first film8and the circuit12. If the circuit12is arranged on the second film14however, then the first film8may also be arranged in the mold along with second film14and the circuit12. If both the first film8and the second film14are being included in the molded part4, then the circuit12may be arranged between the first film8and the second film14. The first film8and the second film14and the circuit12may be flat before being arranged in the mold.

At block208, a liquid resin material may then be injected into the mold and cured to form a solid polymer as the structural layer10to thereby form the molded part4. The resin material may be a thermosetting polymer or a thermoplastic polymer. If the resin is a thermosetting polymer, the mold may be heated to cure the thermosetting polymer. If the resin is a thermoplastic polymer, then the resin may be heated to be in molten form prior to introduction into the mold. The heat from curing a thermoplastic polymer or from the molten thermosetting polymer may cause heating of the first film8and the second film14so that they are pliable.

When at a pliable forming temperature, the first film8and the second film14, may be conformed during the molding process to a desired contoured shape of an interior portion of the mold. Upon cooling of the cured solid polymer, the structural layer10is formed, and the thermoformed first film8and the second film14may retain a contoured shape, e.g. as depicted inFIG. 1. In this way, the mold determines the shape of the molded structural layer10, which determines the shape of molded part4. The first film8and the second film14may be thermoformed from a flat arrangement (e.g.FIG. 3) to have a contoured shape, such as that of the molded part4. The cured polymer of the structural layer10may hold together the various other elements/layers of the molded part4; and the structural layer10gives shape, form, and rigidity to the molded part4.

The first film8, second film14, and the circuit12may be flat before being thermoformed in the molding process as depicted inFIGS. 3-5, and may be thermoformed during the molding process to have a contoured shape as shown inFIGS. 1-2. Although the various layers of the molded part4are shown to be flat inFIGS. 3-5, this is not necessary, and the various layers may be contoured as shown inFIGS. 1 and 2to form the robotic device2, such a robotic lawn mower. The resin may be injected into the mold such when it cures, the structural layer10is arranged adjacent the circuit12, or such that one or more layers or materials separate the structural layer10from the circuit12.

Various operations of embodiments are provided herein. The order in which one or more or all of the operations are described should not be construed as to imply that these operations are necessarily order dependent. Alternative ordering will be appreciated based on this description. Further, not all operations may necessarily be present in each embodiment provided herein.