Multilayer structure for accommodating electronics and related method of manufacture

Patent metadata

Field	Value
Publication number	US-9724869-B2
Application number	US-201414583940-A
Country	US
Kind code	B2
Filing date	Dec 29, 2014
Priority date	Dec 29, 2014
Publication date	Aug 8, 2017
Grant date	Aug 8, 2017

Abstract

Multilayer structure ( 200 ) for electronic devices, including a flexible substrate film ( 102 ) for accommodating electronics, a number of electrical elements ( 204, 206 ) provided to the flexible substrate film, preferably by element of printed electronics and/or surface mounting, a protective layer ( 104 ) laminated onto at least first surface of the substrate film, the protective layer being configured to mask perceivable physical deviation of the substrate, such as uneven surface profile or coloring, substantially at the location of the number of elements, from outside perception, optionally visual perception and/or tactile inspection taking place via the protective layer, and plastic layer ( 106 ) molded over at least second surface of the substrate film opposite to the first surface. A corresponding method of manufacture is presented.

First claim

The invention claimed is:

1. A multilayer structure for electronic devices, the multilayer structure comprising:
a flexible plastic substrate film for accommodating electronics;
a number of electrical elements provided to the flexible plastic substrate film by printed electronics and/or surface mounting;
a protective layer on at least a first surface of the flexible plastic substrate film, the protective layer being configured to mask perceivable physical deviation of the flexible plastic substrate film, such as uneven surface profile or coloring, substantially at the location of the number of electrical elements, from outside perception and/or tactile inspection taking place via the protective layer; and
a plastic layer molded onto at least a second surface of the flexible plastic substrate film opposite to the first surface,
wherein the protective layer includes conductors printed thereon.

2. The structure of claim 1 , wherein the first surface of the flexible plastic substrate film comprises at least part of the number of electrical elements.

3. The structure of claim 1 , wherein the second surface of the flexible plastic substrate film comprises at least part of the number of electrical elements.

4. The structure of claim 1 , wherein the protective layer comprises elastic material to conform, at the interface between the protective layer and the flexible plastic substrate film, to the surface profile of the flexible plastic substrate film provided with the number of electrical elements and having the plastic layer molded on the second surface thereof.

5. The structure of claim 1 , wherein the protective layer is colored to mask the deviation.

6. The structure of claim 5 , wherein the coloring of the protective layer is configured to blot out the deviations, optionally via color pattern.

7. The structure of claim 5 , wherein the coloring of the protective layer substantially follows the coloring of the flexible plastic substrate film.

8. The structure of claim 1 , wherein the protective layer comprises uneven surface profile, optionally with a number of protrusions, ridges, grooves, dimples, surface reliefs, scale pattern, and/or notches.

9. The structure of claim 1 , wherein the protective layer and/or molded layer is flexible, preferably the overall multilayer structure being also flexible.

10. The structure of claim 1 , wherein the flexible plastic substrate film comprises at least one material selected from the group consisting of:
thermoplastic material, plastics, polymer, polycarbonate, polymethylmethacrylate, MS resin, PET, glass, polyimide, and metal.

11. The structure of claim 1 , wherein the protective layer comprises at least one material selected from the group consisting of:
thermoplastic material, TPE (thermoplastics elastomer), plastics, metal, leather, biological material, and textile material.

12. The structure of claim 1 , wherein the protective layer is configured to protect the flexible plastic substrate film against at least one element selected from the group consisting of:
impacts, radiation, light, heat, cold, moisture, and dirt.

13. The structure of claim 1 , wherein the protective layer includes at least one indicative, instructive or decorative element selected from the group consisting of:
coloring, graphics, graphical pattern, light outcoupling or reflecting pattern such as a surface relief pattern, symbol, textual representation, and numerical representation.

14. The structure of claim 1 , wherein the number of electrical elements include at least one element selected from the group consisting of:
a conductor, transistor, diode, resistor, capacitor, integrated circuit, light-emitting element, light detecting element, processing element, memory element, sensor, communications element, electronics sub-assembly, sub-system, and connector.

15. The structure of claim 1 , wherein the flexible plastic substrate film is less than about 300 microns thick, preferably less than about 200 microns thick, and most preferably less than about 150 microns thick.

16. An electronic device, optionally a wristop device, armband device or other portable computer or a controller therefor, comprising the structure of claim 1 .

17. The structure of claim 1 , wherein the protective layer includes a textured surface profile.

18. A multilayer structure for electronic devices, the multilayer structure comprising:
a flexible substrate film for accommodating electronics;
a number of electrical elements provided to the flexible substrate film, by printed electronics and/or surface mounting;
a protective layer on at least a first surface of the flexible substrate film, the protective layer being configured to mask perceivable physical deviation of the flexible substrate film, such as uneven surface profile or coloring, substantially at the location of the number of electrical elements, from outside perception, and/or tactile inspection taking place via the protective layer; and
a plastic layer molded onto at least a second surface of the flexible substrate film opposite to the first surface,
wherein the protective layer is at least partially translucent or opaque to blot out the deviations, optionally further comprising optically substantially transparent windows or regions having regard to predefined wavelengths.

19. A method for manufacturing a multilayer structure for electronic devices, the method comprising:
obtaining a flexible substrate film for accommodating electronics, provided with a protective layer on at least a first surface of the flexible substrate film, the protective layer being configured to mask perceivable physical deviation of the flexible substrate film, such as uneven surface profile or coloring, substantially at the location of a number of electrical elements further provided to the flexible substrate film, from outside perception and/or tactile inspection taking place via the protective layer, and
molding a plastic layer over at least a second surface of the flexible substrate film opposite to the first surface.

20. The method of claim 19 , further comprising thermoforming the electronics-provided substrate or substrate-protective layer laminate to a desired three-dimensional shape.

21. The method of claim 19 , further comprising printing a number of decorative, indicative or instructive features on the flexible substrate film, optionally on the first and/or second surface thereof.

Assignees

• Tactotek Oy
• Tacto Tek Oy

Inventors

• Niskala Paavo
• Saaski Jarmo
• Raappana Pasi
• Heikkinen Mikko
• Sippari Mikko
• Torvinen Jarkko
• Keranen Antti

Classifications

• H05K2201/10545

  Related components mounted on both sides of the PCB · CPC title

• H05K2201/09118

  Moulded substrate · CPC title

• H05K2201/0154

  Polyimide · CPC title

• H05K2201/0145

  Polyester, e.g. polyethylene terephthalate [PET], polyethylene naphthalate [PEN] · CPC title

• H05K2201/0133

  Elastomeric or compliant polymer · CPC title