METHOD FOR EMBEDDING CONDUCTORS AND STRUCTURE PRODUCED BY SAME

Abstract: A method, and an article produced according to the method, for embedding conductors in a structure having a signal distribution function associated therewith such as a vehicle instrument panel. The method includes embedding a conductor (10) in a film (12), and moulding a material (14) to the film (12) such that the material and the film integrally form the structure. The method also includes attaching a connector (18) to the integral structure so that the connector (18) is provided in communication with the conductor (10).

Description: METHOD FOR EMBEDDING CONDUCTORS AND STRUCTURE PRODUCED BY SAME This invention relates to a moulding method for embedding conductors in a material and a structure, such as a vehicle instrument panel or the like, produced by that method. Typically, a vehicle instrument panel assembly includes multiple wire harnesses providing electrical communication for various electronic instrument panel components such as a sound system, anti-lock brake module, engine control module, air bag module, as well as many other components. As is readily apparent, this assembly can consume a substantial amount of space beneath the instrument panel. It is, therefore, desirable to provide a method and structure for integrating such wire harnesses or other electrical conductors and/or connectors in a vehicle instrument panel or other large vehicle interior subsystems having signal distribution applications. Such a method and structure would permit more efficient use of vehicle space while also improving manufacturing time and costs, as well as product performance. Ideally, such a method and structure would also be environmentally robust with rapid, cost effective and robust means for establishing electrical connections associated therewith. In that regard, various techniques for attaching, moulding and embedding electrical conductors and/or components are known in the art, such as those disclosed in U.S. Patent Nos. 5,462,622 issued to Small et al . , 5,220,488 issued to Denes, and 4,646,436 issued to Crowell et al. Such techniques, however, are not applicable to the integration of wire harnesses or other electrical conductors and/or connectors in vehicle instrument panel or other large vehicle interior subsystems having signal distribution applications. Accordingly, it is the principle object of the present invention to provide a method for embedding conductors in a structure such as a vehicle instrument panel or other large vehicle interior subsystems having signal distribution applications . Another object of the present invention is to provide an article, such as a vehicle instrument panel or other large vehicle interior subsystems having signal distribution applications, produced in accordance with the method for embedding conductors in a structure. According to the present invention, a method is provided for embedding conductors m a structure having a signal distribution application associated therewith such as a vehicle instrument panel. The method comprises embedding a conductor m a film, and moulding a material to the film such that the material and the film integrally form the structure. The method also comprises attaching a connector to the integral structure so that the connector is provided in communication with the conductor. According to an embodiment of the present invention, a method is provided for embedding electrical conductors in a structure such as a vehicle instrument panel or the like. Such an embodiment of the method comprises embedding an electrical conductor in a film, and moulding a polymer material about the film such that the material and the film integrally form the structure. Such an embodiment of the method also comprises embedding an electrical connector m the integral structure so that the electrical connector is provided in electrical communication with the electrical conductor. The invention will now be described, by way of example, with reference to the accompanying drawings, in which: Figure la is a cross-sectional view of a film with conductors for use m the method and structure of the present invention; Figure lb is a cross-sectional view of a film with conductors moulded to a material according to the method and structure of the present invention; - 1 - Figure lc is a cross-sectional view of a film with conductors moulded to a material having interconnects according to the method and structure of the present invention; Figure 2a is a cross-sectional view of an alternative film with conductors for use in the method and structure of the present invention; Figure 2b is a cross-sectional view of an alternative film with conductors moulded to a material according to the method and structure of the present invention; and Figure 2c is a cross-sectional view of an alternative film with conductors moulded to a material having interconnects according to the method and structure of the present invention. With reference to the drawings, the preferred embodiment of the present invention will now be described. Referring first to Figure la, a cross-sectional view of a film with conductors for use m the method and structure of the present invention is shown. As seen therein, a plurality of conductors (10) are embedded into a film (12) . In that regard, as used herein, the term embedded is not intended to be defined as completely within. Rather, embedded is defined herein as at least partially within. Conductors (10) are preferably insulated wires, but other types of conductors may also be used including bare wires, metal strands or optical fibres. Conductors (10) may be of any pattern, including simply multiple parallel conductors such as in a wire harness. While conductors (10) are preferably embedded into film (12) ultrasonically, other techniques well known in the art may also be used. Similarly, while film (12) is preferably a polymer, and more preferably a monolithic polymer, other materials and/or structures may be used including, but not limited to, multi- laminar polymers, adhesive-coated metal foils/films, adhesive-coated polymers, metal/polymer laminates/composites, reinforced polymers, and ceramic and glass layers. The material of film (12) may also be modified with various types of fillers. If a polymer, film (12) is generally an engineering thermoplastic resin typically having a thickness of approximately 5-10 mils, although other resins and dimensions may be used. Referring next to Figure lb, a cross-sectional view of the film (12) with conductors (10) of Figure la is shown moulded to a material according to the method and structure of the present invention. Preferably, film (12) is placed onto the face of an injection moulding tool (not shown), with insulated wires (10) facing into the centre of the tool cavity. The injection moulding tool is subsequently closed and injected with a material for final moulding of a part (14) . The resulting moulded part (14), such as a vehicle instrument panel or another large vehicle interior subsystem having signal distribution applications, has signal traces (conductors (10) ) embedded just under the surface (16) of the part (14) . In the example discussed above, wherein the film has a thickness of approximately 5 mils, moulded part (14) will have circuit traces (10) embedded approximately 3 mils under surface (16) . As described above, moulded part (14) is preferably injection moulded, such as by blow moulding or low pressure moulding. However, moulded part (14) may also be formed by other moulding processes well known in the art including, but not limited to, transfer moulding, compression moulding, lamination, vacuum autoclaving, and co-extrusion. Similarly, while the location for conductors (10) in moulded part (14) described above is preferable, it should be noted that conductors (10) may be located anywhere on or in moulded part (14), including surface (16) or within moulded part (14) . In that regard, conductors (10) need not be proximate surface (16) , nor run parallel to surface (16) or any other surface of moulded part (14) . The only requirement concerning the location of conductors (10) is that some portion thereof be located close enough to a surface of moulded part (14) so that external communication may be established therewith, preferably as described in greater detail below with regard to Figure lc. The material chosen for moulded part (14) is preferably a polymer such ds a thermoplastic resin, although other types of materials may be used including, but not limited to, thermoset polymers, elastomers, molten metals, and sol- gels (ceramics) . Moreover, the material is also preferably similar to that of film (12) . In that regard, the thermoplastic resin used for moulded part (14) may be modified with a filler, or have a different melt viscosity than that of film (12) . In any event, the thermoplastic resin used is preferably either the chemical equivalent or at least miscible with respect to film (12) . For example, if the film (12) comprises polystyrene, the thermoplastic resin used for moulded part (14) may comprise PPO injection moulded resin. Alternatively, film (12) and moulded part (14) need not comprise miscible materials. Instead, an adhesive could be applied between film (12) and part (14) . While such an adhesive could be continuous, it could also be discontinuous to provide for thermal expansion of film (12) and/or part ( 14) . Referring next to Figure lc, a cross-sectional view of the film (12) with conductors (10) moulded in part (14) is shown having interconnects according to the method and structure of the present invention. More specifically, the method and structure of the present invention also entail providing for the interconnection of external conductors (not shown) to the embedded conductors (10) with the use of at least one interconnect device. While such a device is preferably an embedded insulation displacement connector (18), other similar devices or techniques may also be used. Insulation displacement connectors (18) are embedded or staked into predetermined locations of the moulded part (14) . While connectors (18) are preferably embedded into the material of moulded part (14) ultrasonically, other- techniques well known in the art may also be used. In that - h - regard, the design of the connectors (18) , well known in the art, not only provides for energy coupling to an ultrasonic horn for embedding m moulded part (14) , but also incorporates features which establish electrical contact between conductors (10) and connectors (18) . Connectors (18) can then be connected to conventional external connectors (not shown) or soldered/crimped (not shown) . Once again, as used herein, the term embedded is not intended to be defined as completely within. Rather, embedded is defined herein as at least partially within. Other techniques may also be mixed with the basic concept of the method and structure of the present invention. In that regard, referring now to Figure 2a, a cross-sectional view of an alternative film (20) with conductors (22) for use in the method and structure of the present invention is shown. As seen therein, prior to embedding, film (20) film may be provided with conventional lithographed circuitry (24) on one or both sides. Circuitry (24) could also be formed on film (20) through other techniques such as the embossing or printing of a conductor. As with conductors (10) described above with respect to Figures la-c, circuitry (24) may be of any pattern. Referring next to Figure 2b, a cross-sectional view of the film (20) with conductors (22) of Figure 2a is shown moulded to a material according to the method and structure of the present invention. As seen therein, a moulded part (26) is formed with conductors (22) located just beneath a surface (28) of moulded part (26) , and with circuitry (24) located on surface (28) . In that regard, the moulding of part (26) is preferably undertaken in the same fashion as described above with respect to Figure lb. Referring finally to Figure 2c, a cross-sectional view of the film (20) with conductors (22) moulded in part (26) is shown having insulation displacement connectors (30) according to the method and structure of the present invention. As described above with respect to Figure lc, connectors (30) are embedded or staked, preferably ultrasonically, into predetermined locations of the moulded part (26) to establish communication between conductors (22) and connectors (30) . As also seen in Figure 2c, however, m this embodiment of the method and structure of the present invention, connectors (30) may also be provided in communication with circuitry (24) , such as by soldering (not shown) or other known techniques. In any event, connectors (30) can once again then be connected to conventional external connectors (not shown) or soldered/crimped (not shown) . The method and structure of the present invention may also be extended to provide for multi-layer circuits. In that regard, following moulding according to the method of the present invention as described above, the resulting structure may have additional outer circuitry defined using conventional lithography or plating processes. Referring again to Figures la-c, such circuitry may be interconnected with the ultrasonically embedded conductors (10) through the use of the insulation displacement connectors (18) previously described, plated through holes (not shown) , or other similar features. Multiple layers (not shown) of ultrasonically embedded conductors (10) can also be added to provide for additional layers of circuitry. Another related structure involves the use of embedded conductors (10) on both sides (not shown) of the film (12) to be placed in the injection moulding tool. Once again, interconnection between such conductors (10) may be provided through the use of the insulation displacement connectors (18) previously described, plated through holes (not shown), or other similar features. Once again, while the method and structure of the present invention are preferably used with engineering and thermoplastic resins, they are not necessarily limited to such materials. Lower temperature thermoplastic resins and/or elastomers can also be used provided the thermal demands of subsequent connections and component attachment techniques are met. The method and structure of the present invention also ctre not limited to thermoplastic resins, but may have utility with thermosetting resins such as phenol- formaldehyde or anhydride cure epoxy resins. The use of the latter provides less sensitivity to film/moulding resin compatibility issues. Additional materials for film (12) and/or moulded part (14) have been set forth in greater detail above. It should also be noted that the materials used according to the method and structure of the present invention require material characteristics which meet various electrical/electronic specifications concerning manufacturing and operational environments. More specifically, the materials must exhibit adequate physical, thermal, environmental, and electrical properties to meet the requirements of the intended application. Structures produced according to the method of the present invention permit functions traditionally provided using many separate components such as wire harnesses and/or other conductors and/or connectors to be combined with each other and a vehicle instrument panel or another large vehicle interior subsystem having signal distribution applications to form a single integrated component. Because of the various designs three-dimensional moulded circuitry can take, circuitry and interconnections become integrated into the subsystem assembly infrastructure. Thus, designers can integrate circuitry with plastics to reduce cost, size and parts count, while increasing reliability and facilitating manufacturability. The reduction of individual parts requiring assembly/disassembly and interconnection also increases reliability and serviceability in the field and lowers manufacturing cycle time. Structures produced according to the method of the present invention also provide for improved recyclability, requiring fewer process steps and resulting in more recoverable materials. Metal content can be easily stripped by wet chemical processing and separated for reclamation. Remaining polymers are generally 100O recyclable . As is readily apparent from the foregoing detailed description, the present invention provides a method for embedding conductors m a structure such as a vehicle instrument panel or other large vehicle interior subsystems having signal distribution applications. Still further, the present invention also provides an article, such as a vehicle instrument panel or other large vehicle interior subsystems having signal distribution applications, produced in accordance with the method of the present invention for embedding electrical conductors in a structure.

Claims: CLAIMS 1. A method for embedding conductors in a structure having a signal distribution application associated therewith such as a vehicle instrument panel, the method comprising: embedding at least one conductor (10) in a film (12) ; moulding a material (14) to the film (12) such that the material and the film integrally form the structure; and attaching a connector (18) to the integral structure so that the connector is provided m communication with the conductor (10) . 2. A method as claimed in claim 1, wherein the material is moulded to the film such that the conductor of the film is proximate a surface of the integral structure. 3. A method as claimed in claim 1 or 2, wherein embedding a conductor m the film includes ultrasonically heating the film. 4. A method as claimed in any one of claims 1 to 3, wherein attaching a connector to the integral structure includes ultrasonically embedding a connector in the structure. 5. A method as claimed in any one of claims 1 to 4, wherein moulding a material to the film such that the material and the film integrally form the structure includes: providing a moulding tool; orienting the film relative to the moulding tool; and injecting the material into the moulding tool. 6. A method as claimed in any one of the preceding claims, wherein the material comprises a polymer. 7. A method as claimed in any one of the preceding claims, wherein the film comprises a polymer. 8. A method as claimed in any one of the preceding claims, wherein the conductor and the connector are optical 9. A method as claimed in any one of claims 1 to 7, wherein said conductor is an electrical conductor and said connector is an electrical connector. 10. A method as claimed m claim 9, wherein said electrical connector comprises an insulation displacement connector.

Inventors: BELKE ROBERT EDWARD, TODD MICHAEL GEORGE, TRUBLOWSKI JOHN, BELKE, ROBERT, EDWARD, TODD, MICHAEL, GEORGE, TRUBLOWSKI, JOHN
Applicants: FORD FRANCE, FORD MOTOR CANADA, FORD MOTOR CO, FORD WERKE AG, FORD FRANCE S.A., FORD MOTOR COMPANY, FORD MOTOR COMPANY LIMITED, FORD MOTOR COMPANY OF CANADA LIMITED, FORD WERKE A.G.
Application year: 1997
Main classification: B60R16
IPC codes: B60R16