In-molded resistive and shielding elements
View Patent ↗An article of manufacture having an in-molded resistive and/or shielding element and method of making the same are shown and described. In one disclosed method, a resistive and/or shielding element is printed on a film. The film is formed to a desired shape and put in an injection mold. A molten plastic material is introduced into the injection mold to form a rigid structure that retains the film.
1. An article of manufacture having at least one of an in-molded resistive element and an in-molded shielding element, comprising: a thermo-formable plastic film having a front surface and a back surface; at least one printed thermo-formable conductive ink layer to create at least one of the in-molded resistive element and the in-molded shielding element printed on the front or back surface of the thermo-formable plastic film; at least one printed thermo-formable dielectric layer applied on top or underneath the printed thermoformable conductive ink layer; and a plastic support structure, wherein the front or back surface of the thermo-formable plastic film faces the plastic support structure, and wherein the thermo-formable plastic film is bonded to the plastic support structure.
2. The article of manufacture of claim 1 , wherein at least a portion of the front or back surface of the film is exposed to the plastic support structure.
3. The article of manufacture of claim 1 , wherein at least a portion of the front or back surface of the film is coated with a dielectric layer.
4. The article of manufacture of claim 1 , wherein the at least one of the in-molded resistive element and the in-molded shielding element is not exposed to the plastic support structure.
5. The article of manufacture of claim 1 , wherein the at least one of the in-molded resistive element and the in-molded shielding element is exposed to the plastic support structure.
6. The article of manufacture of claim 1 , wherein the film is in-between a front surface and a back surface of the plastic support structure.
7. The article of manufacture of claim 1 , wherein at least one of the front surface and the back surface of the film are secured to at least one of a front surface and a back surface of the plastic support structure.
8. The article of manufacture of claim 1 , further comprising at least one connector electrically connected to the at least one of the in-molded resistive element and the in-molded shielding element, wherein a portion of the at least one connector projects away from the plastic support structure.
9. The article of manufacture of claim 1 , comprising at least one connector molded into the plastic support structure and electrically connected to the at least one of the in-molded resistive element and the in-molded shielding element.
10. The article of manufacture of claim 1 , further comprising indicia related to a function of the article of manufacture, wherein the indicia is painted on one surface of the plastic support structure and is visible on the other side of the plastic support structure.
11. The article of manufacture of claim 1 , wherein the at least one shielding element is formed to block radiated emissions.
12. The article of manufacture of claim 1 , wherein the at least one shielding element is formed to allow radiated emissions to be emitted from predetermined areas of the film.
13. The article of manufacture of claim 1 , wherein the at least one resistive element is formed to provide a voltage drop in a circuit.
14. The article of manufacture of claim 1 , wherein the film comprises the shielding element printed one of the surfaces of the film and further comprising: the surface of said film having an A-surface and a B-surface, wherein at least one of the A-surface and the B-surface of the film is secured to at least one of an A-surface and a B-surface of the plastic support structure; wherein said film is in-between a top of the plastic support structure and a bottom of the plastic support structure; and wherein the film is secure to the plastic support structure to form a three dimensional object having a plurality of surfaces, the surfaces being at least one of a flat surface and a curved surface.
15. The article of manufacture of claim 1 , wherein the film comprises the shielding element printed one of the surfaces of the film and further, comprising: the film the surface of said film having an A-surface and a B-surface, wherein at least one of the A-surface and the B-surface of the film is secured to at least one of an A-surface and a B-surface of the plastic support structure; wherein said film is in-between a top of the plastic support structure and a bottom of the plastic support structure;
and wherein the film is secured to the plastic support structure to form a three dimensional object having a plurality of surfaces, the surfaces being at least one of a flat surface and a curved surface.