Patent ID: 12233630

DETAILED DESCRIPTION OF THE EMBODIMENTS

In order to make the above objects, features and advantages of the present disclosure more obvious and understandable, the specific embodiments of the present disclosure will be illustrated in detail below in conjunctions with the accompanying drawings. In the following description, many specific details are set forth in order to assist readers in fully understanding of the present disclosure. However, the present disclosure can be implemented in many other ways than described herein, and those skilled in the art can make similar improvements without departing from the connotation of the present disclosure. Therefore, the present disclosure is not limited by the specific embodiments disclosed below.

In the description of the present disclosure, it should be understood that orientation or positional relationships indicated by terms “center”, “longitudinal”, “transverse”, “length”, “width”, “thickness”, “upper”, “lower”, “front”, “rear”, “left”, “right”, “vertical”, “horizontal”, “top”, “bottom”, “inner”, “outer”, “clockwise”, “counterclockwise”, “axial”, “radial”, “circumferential”, etc. are based on orientation or positional relationship shown in the drawings, which are merely to facilitate the description of the present disclosure and simplify the description, not to indicate or imply that the device or elements must have a particular orientation, be constructed and operated in a particular orientation, and therefore cannot be construed as a limitation on the present disclosure.

In addition, the terms “first” and “second” are used for description only, and cannot be understood as indicating or implying relative importance or implicitly indicating the number of technical features described. Thus, the features defined with “first” and “second” may include at least one of the features explicitly or implicitly. In the description of the present disclosure, the meaning of “plurality” is at least two, such as two, three, etc., unless explicitly defined otherwise.

In the present disclosure, unless explicitly specified and limited otherwise, the terms “mounting”, “connecting”, “connected”, “fixed” and the like should be understood in a broad sense. For example, it may be a fixed connection or a detachable connection, or an integration, may be a mechanical connection or electrical connection, may be a direct connection, or may be an indirect connection through an intermediate medium, may be the connection between two elements or the interaction relationships between two elements, unless explicitly defined otherwise. The specific meanings of the above terms in the present disclosure can be understood by one of those ordinary skills in the art according to specific circumstances.

In the present disclosure, unless explicitly specified and limited otherwise, the first feature being “on” or “below” the second feature may be that the first and second features are in a direct contact, or the first and second features are in an indirect contact through an intermediate medium. Moreover, the first feature being “over”, “above” and “on” the second feature may be that the first feature is directly above or obliquely above the second feature, or simply means that the first feature is higher than the second feature in horizontal direction. The first feature being “beneath”, “under”, and “below” the second feature may be that the first feature is directly below or obliquely below the second feature, or simply means that the first feature is lower than the second feature in horizontal direction.

It should be noted that when an element is referred to as being “fixed” or “disposed on” another element, it may be directly on another element or there may also be an intermediate element therebetween. When an element is considered to be “connected” to another element, it may be directly connected to another element or there may be an intermediate element therebetween. As used herein, the terms “vertical”, “horizontal”, “upper”, “lower”, “left”, “right”, and similar expressions are for illustration only and are not meant to be the only embodiments.

Appearance structures such as conventional home appliances, automotive interior parts, consumer electronic products are generally assembled by components such as plastic components and integrated circuit boards behind the plastic components. The integrated circuit board includes a printed circuit board and an electronic component welded to the printed circuit board, and has disadvantages such as complex structure, heavy volume, cumbersome manufacturing process, poor waterproof performance, poor weather resistance, and poor impact resistance.

In order to solve the above problems, an in-mold electronic (IME) component has proposed. The IME component is formed by sealing a circuit board and an electronic component on the circuit board in a plastic component through an injection molding process. In order to electrically connect the electronic component sealed in the plastic component to external components, it is generally necessary to lead the circuit board and a printed circuit on the circuit board out of the plastic component by arranging connecting cables, and bend it to a rear surface of the IME component, to facilitate the electrical connection to the external components. However, in a process of forming the IME component, a high-temperature injection molding process is required to be performed, and thus a substrate of the circuit board is easy to age and become brittle. Therefore, the circuit board corresponding to the wiring and the printed circuit on the circuit board are prone to brittle fracture when bent, resulting in failure of the electrical connection to the external components.

In order to solve the above problems, an IME component is provided. As shown inFIGS.1and2, in an embodiment, the IME component includes a first film layer100, a functional module200, a plastic layer300, and a lead-out terminal400. The first film layer100is provided at a top surface600of the IME component. The functional module200includes a circuit layer210and an electronic component220. The electronic component220includes a display unit221and a touch unit222. The display unit221and the touch unit222are both electrically connected to the circuit layer210. The top surface600of the IME component includes a display area610and a touch area620. The display area610is positioned corresponding to the display unit221, and the touch area620is positioned corresponding to the touch unit222. Information generated by the display unit221can be displayed on the display area. The plastic layer300is used to seal the functional module200. One end of the lead-out terminal400is electrically connected to the circuit layer210, and the other end of the lead-out terminal400is lead out to a rear surface700of the IME component. The rear surface700and the top surface600of the IME component are provided opposite to each other. By providing the lead-out terminal400, the electronic component220sealed in the plastic layer300can be directly electrically connected to external components, the connecting cables can be avoided, thereby avoiding the bending and brittle fracture of the connecting cables, ensuring the reliability of the electrical connection.

In a specific embodiment, as shown inFIGS.1and4, the display unit221is an LED lamp. Light emitted by the LED lamp is indicated by dotted lines inFIGS.1and4. The light is distributed in the display area610of the IME component. The light emitted by the LED lamp can go through the display area610of the IME component. The touch unit222includes a transparent conductive layer. The transparent conductive layer can be made of conductive materials, such as indium tin oxide (ITO), indium zinc oxide (IZO), fluorine-doped tin oxide (FTO), aluminum-doped zinc oxide (AZO), gallium-doped Zinc oxide (GZO), antimony doped tin oxide (ATO), polyethylene dioxythiophene (PEDOT), transparent conductive polymer materials, graphene, carbon nanotubes or metal mesh.

In an embodiment, as shown inFIG.1, the IME component further includes a second film layer500. The second film layer500is provided on the rear surface700of the IME component. The plastic layer300is located between the first film layer100and the second film layer500. The circuit layer210is located at a side of the second film layer500adjacent to the plastic layer300. The first film layer100is provided with a decorative layer110on a side thereof away from the top surface600. The decorative layer110is provided with a through hole111at a position corresponding to the display unit221. The light emitted by the display unit221can go through the display area610of the IME component through the through hole111. In addition, as shown inFIG.1, the second film layer500is provided with a via hole510. The via hole510is filled with a conductive material410. The lead-out terminal400includes a flexible printed circuit (FPC)420and the conductive material410filled in the via hole510. One end of the conductive material410is electrically connected to the circuit layer210, and the other end of the conductive material410is electrically connected to the FPC420, such that the electronic component220sealed in the plastic layer300can be electrically connected to the external components sequentially through the circuit layer210, the conductive material410in the via hole510, and the FPC420.

In an embodiment, the circuit layer210may be made of conductive silver paste, conductive carbon paste, or conductive copper paste, but is not limited hereto. The circuit layer210is formed on the second film layer500by printing. Methods of printing include inkjet printing, offset printing, gravure printing, screen printing, and flexographic printing, but are not limited hereto. The conductive material410in the via hole510may be conductive silver paste, conductive carbon paste, or conductive copper paste, but is not limited hereto. In one embodiment, the conductive material410in the via hole510can be filled in the via hole510by double-sided printing.

In an embodiment, a method for manufacturing the IME component shown inFIG.1is shown inFIG.8. Firstly, the decorative layer110is printed on a side of the first film layer100, and then, the via hole510is formed in the second film layer500by laser or computer numerical control (CNC) process, and then, the conductive material410is filled in the via hole510by double-sided printing. Then, the circuit layer210is printed on the second film layer500, and the transparent conductive layer is provided on the circuit layer210. Then, the transparent conductive layer is patterned by etching or other processes to form the touch unit222electrically connected to the circuit layer210. Then, pins of the LED lamp are connected to the circuit layer210, such that the circuit layer210, the display unit221and the touch unit222are all integrated on one side of the second film layer500. Then, the second film layer500is processed according to specific requirements. For example, the second film layer500can be bent into a curved surface, such that sizes and shapes of the second film layer500and the functional module200on the second film layer500can meet specific size and shape requirements. Then, the first film layer100and the second film layer500are provided on an inner surface of a mold cavity of a mold. The decorative layer110on the first film layer100is placed close to the mold cavity of the mold. The circuit layer210, the display unit221, and the touch unit222on the second film layer500are also placed close to the mold cavity of the mold. Then, a high-temperature molten plastic material is injected into the mold cavity of the mold through the injection molding process to form the plastic layer300. The decorative layer110on the first film layer100, the circuit layer210, the display unit221, and the touch unit222on the second film layer500are sealed in the plastic layer300through the plastic layer300. Finally, the conductive material410filled in the via hole510of the second film layer500is bound to the FPC420at an end away from the circuit layer210.

In the embodiment shown inFIG.1, the via hole510is formed in the second film layer500, and the conductive material410is filled in the via hole510. On the one hand, the electronic component220sealed in the plastic layer300can be directly electrically connected to the external components through the conductive material410in the via hole510, the connecting cables can be avoided, thereby avoiding the bending and brittle fracture of the connecting cables, and thus ensuring reliability of the electrical connection between the electronic component220in the plastic layer300and the external components. On the other hand, the conductive material410can further seal the via hole510on the second film layer500to prevent high-temperature molten plastic fluid from flowing out from the via hole510on the second film layer500when the plastic layer300is formed by the subsequent injection molding process, thereby improving the processing yield of the IME component. In addition, the circuit layer210, the display unit221, and the touch unit222on the second film layer500are sealed in the plastic layer300through the plastic layer300, such that the appearance structure of the IME component is lighter and thinner and is not detachable, and has advantages of moisture resistance, weather resistance, impact resistance and the like. In addition, the decorative layer110on the first film layer100is sealed in the plastic layer300through the plastic layer300, such that the IME component has advantages of diverse pattern changes, resistance to friction, resistance to oxidation and discoloration, corrosion resistance, environmental protection, and the like.

In addition, it should be noted that in the embodiment shown inFIG.1, the display unit221is located directly below the through hole111, and the light emitted by the display unit221can directly go through the display area610of the IME component through the through hole111. In other embodiments, as shown inFIG.2, two display units221may also be located on opposite sides of the through hole111, respectively. More specifically, the two display units221are respectively located on a side of the circuit layer210away from the decorative layer110, respectively, such that the light emitted by the two display units221is transmitted to the through hole111through the plastic layer300. Additionally, in the embodiment shown inFIG.2, a guiding lens223may be provided at a light outlet of each display unit221. The guiding lens223can guide the light emitted by the left display unit221to the right, and guide the light emitted by the right display unit221to the left. Therefore, the light emitted by the display units221is transmitted to the through hole111through the guiding lens223, and then transmitted to the display area610of the IME component through the through hole111. As shown inFIG.3, in another embodiment, the display unit221and the touch unit222may also be laminated. The display unit221and the touch unit222are both located below the through hole111, and the display unit221is located above the touch unit222. An insulating layer800is further provided between the display unit221and the touch unit222. In this case, the display area610and the touch area620of the top surface600of the IME component coincided with each other, which both are located above the through hole111.

In another embodiment, as shown inFIG.2andFIG.4, the decorative layer110is provided on the side of the first film layer100away from the top surface600. The circuit layer210is provided on a side of the decorative layer110away from the first film layer100. The plastic layer300is located on a side of the circuit layer210away from the decorative layer110and is used to seal the circuit layer210and the electronic component220. The lead-out terminal400may be a pin header430. The pin header430includes a connecting pin431and a pin head432. A transverse size of the connecting pin431is greater than that of the pin head432. The connecting pin431is electrically connected to the circuit layer210. The pin head432extends through the plastic layer300, and protrudes from the rear surface700of the IME component.

In an embodiment, a method for manufacturing the IME component shown inFIG.4is shown inFIG.9. Firstly, the decorative layer110is printed on the first film layer100, and then, the circuit layer210is printed on the decorative layer100, and the transparent conductive layer is provided on the circuit layer210. The transparent conductive layer is patterned by etching or other processes to form the touch unit222electrically connected to the circuit layer210. Then, pins of the LED lamp are connected to the circuit layer210, such that the circuit layer210, the display unit221and the touch unit222are integrated on one surface of the first film layer100. Then, the first film layer100is processed according to specific requirements. For example, the first film layer100is bent into a curved surface, such that sizes and shapes of the first film layer100and the functional module200on the first film layer100can meet the specific size and shape requirements. Then, the connecting pin431of the pin header430is fixed and electrically connected to the circuit layer210. The fixing method can be, but not limited to, a method of epoxy curing or thermoplastic resin injection molding. Finally, the plastic layer300is formed on a side of the circuit layer210away from the first film layer100through an injection molding process, such that the decorative layer110on the first film layer100, the circuit layer210, the display unit221, and the touch unit222of the functional module200are sealed in the plastic layer300though the plastic layer300. In addition, a part of the lead-out terminal400is also embedded in the plastic layer300.

In the embodiment shown inFIG.4, through providing the pin header430, and reasonably deploying the structure of the pin header430, the connecting pin431and a part of the pin head432of the pin header430are sealed in the plastic layer300, and the connecting pin431of the pin header430is electrically connected to the circuit layer210. The pin head432extends through the plastic layer300and protrudes from the rear surface700of the IME component, such that the electronic component220sealed in the plastic layer300can be directly electrically connected to the external components through the pin header430, the connecting cables can be avoided, thereby avoiding the bending and brittle fracture of the connecting cables, and ensuring the reliability of the electrical connection between the electronic components220sealed in the plastic layer300and the external components. In addition, the circuit layer210, the display unit221, and the touch unit222of the functional module200are sealed in the plastic layer300through the plastic layer300, such that the appearance structure of the IME component is lighter and thinner and is not detachable, and has advantages of moisture resistance, weather resistance, impact resistance and the like. In addition, the decorative layer110on the first film layer100is sealed in the plastic layer300through the plastic layer300, such that the IME component has advantages of diverse pattern changes, resistance to friction, resistance to oxidation and discoloration, corrosion resistance, environmental protection, and the like.

In addition, it should be noted that in the embodiment shown inFIG.4, two display units221are respectively located on opposite sides of the through hole111, and light emitted by the two display units221is transmitted to the through hole111through the plastic layer300. It is understood that, in other embodiments, the display unit221and the touch unit222may also be laminated. As shown inFIG.5, the display unit221and the touch unit222are located below the through hole111, and the display unit221is located below the touch unit222. An insulating layer800is provided between the display unit221and the touch unit222. It should be noted that the touch unit222and the insulating layer800are transparent layers. The light emitted by the display unit221can reach the through hole111sequentially through the insulating layer800and the touch unit222, and then transmitted to the display area610of the IME component through the through hole111. In this case, the display area610and the touch area620of the top surface600of the IME component coincided with each other, and which both are located above the through hole111.

In addition, in the embodiments shown inFIGS.1to7, the through holes111are provided on the decorative layer110. The light emitted by the display unit221can go through the display area610of the IME component through the through hole111. It is understood that, in other embodiments, a blind hole may be provided in the decorative layer110instead of the through hole111, as long as the blind hole can transmit light, and the light emitted by the display unit221can go through the display area610of the IME component through the blind hole.

In addition, in the embodiments shown inFIGS.4and5, the pin header430is a male pin header. It is understood that, in other embodiments, the pin header430may also be a female pin header.

As shown inFIG.6, the pin header430includes a connecting pin431, a coil portion433, and a protective shell435. The connecting pin431is electrically connected to the coil portion433. An insertion hole434is formed in the coil portion433. The protective shell435is sleeved on the coil portion433. The protective shell435protrudes from the plastic layer300and protrudes from the rear surface700of the IME component. In the embodiments shown inFIGS.4and5, the pin header430is the male pin header. When the plastic layer300is formed by an in-mold injection process, it is necessary to provide a groove in a mold cavity of a lower mold, to keep away from a protruding end of the pin head432, and it is necessary to align the groove with the pin head432strictly. Otherwise, during a process of closing an upper mold910and the lower mold920, the lower mold920will easily damage the pin head432. In the embodiment shown inFIG.6, the pin header430is the female pin header. A process of forming the plastic layer300through the in-mold injection process is shown inFIG.7. As the coil portion433is covered with the protective shell435, the protective shell435has a transverse size much greater than that of the pin head432, such that the lower mold920can be aligned with the pin header430more easily. During the process of closing the upper mold910and the lower mold920, it is only necessary to align the groove921of the lower mold920with the protective shell435of the pin header430. Finally, the plastic layer300is formed on the side of the circuit layer210away from the first film layer100through the injection molding process, such that the decorative layer110on the first film layer100, the circuit layer210, the display unit221, and the touch unit222of the functional module200are sealed in the plastic layer300through the plastic layer300. In addition, a part of the lead-out terminal400is embedded in the plastic layer300. The lead-out terminal400with a portion sealed in the plastic layer300is shown inFIG.6as the connecting pin431and the protective shell435with a portion covering the coil portion433, of the pin header430. It is understood that, in an embodiment, the male pin header shown inFIGS.4and5can be inserted into the insertion hole434of the female pin header shown inFIG.6to achieve an electrical connection.

According to the above IME components, through rationally deploying structures and connecting relationships between the first film layer100, the functional module200, the plastic layer300and the lead-out terminal400, the first film layer100is provided at the top surface600of the IME component, the functional module200is sealed in the plastic layer300, and one end of the lead-out terminal400is electrically connected to the circuit layer210, and the other end of the lead-out terminal400is led out to the rear surface700of the IME component. Therefore, on the one hand, the appearance structure of the IME component is lighter and thinner, and is not detachable, and has advantages of moisture resistance, weather resistance, impact resistance and the like. On the other hand, the electronic component220sealed in the plastic layer300can be directly electrically connected to the external components through the lead-out terminal400, the connecting cables can be avoided, thereby avoiding the bending and brittle fracture of the connecting cables, and thus ensuring the reliability of the electrical connection between the electronic component220sealed in the plastic layer300and the external components.

The technical features of the above-mentioned embodiments can be combined arbitrarily. In order to simply the description, all possible combinations of the technical features in the above-mentioned embodiments are not described. However, as long as there is no contradiction in the combinations of these technical features, they should be considered to be fallen into the range described in the present specification.

Only several implementations of the present disclosure are illustrated in the above-mentioned embodiments, and the description thereof is relatively specific and detailed, but it should not be understood as a limitation on the scope of the present disclosure. It should be noted that for those of ordinary skill in the art, without departing from the concept of the present disclosure, several modifications and improvements can be made, which all fall within the protection scope of the present disclosure. Therefore, the protection scope of the present disclosure shall be subject to the appended claims.