WO2013180132A1 - 射出成形品及びその製造方法 - Google Patents
射出成形品及びその製造方法 Download PDFInfo
- Publication number
- WO2013180132A1 WO2013180132A1 PCT/JP2013/064784 JP2013064784W WO2013180132A1 WO 2013180132 A1 WO2013180132 A1 WO 2013180132A1 JP 2013064784 W JP2013064784 W JP 2013064784W WO 2013180132 A1 WO2013180132 A1 WO 2013180132A1
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- WIPO (PCT)
- Prior art keywords
- conductive adhesive
- contact pin
- pin
- injection
- contact
- Prior art date
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- G—PHYSICS
- G06—COMPUTING; CALCULATING OR COUNTING
- G06F—ELECTRIC DIGITAL DATA PROCESSING
- G06F3/00—Input arrangements for transferring data to be processed into a form capable of being handled by the computer; Output arrangements for transferring data from processing unit to output unit, e.g. interface arrangements
- G06F3/01—Input arrangements or combined input and output arrangements for interaction between user and computer
- G06F3/03—Arrangements for converting the position or the displacement of a member into a coded form
- G06F3/041—Digitisers, e.g. for touch screens or touch pads, characterised by the transducing means
- G06F3/044—Digitisers, e.g. for touch screens or touch pads, characterised by the transducing means by capacitive means
- G06F3/0445—Digitisers, e.g. for touch screens or touch pads, characterised by the transducing means by capacitive means using two or more layers of sensing electrodes, e.g. using two layers of electrodes separated by a dielectric layer
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
- B29C45/14065—Positioning or centering articles in the mould
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
- B29C45/14467—Joining articles or parts of a single article
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
- B29C45/14639—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles for obtaining an insulating effect, e.g. for electrical components
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- G—PHYSICS
- G06—COMPUTING; CALCULATING OR COUNTING
- G06F—ELECTRIC DIGITAL DATA PROCESSING
- G06F1/00—Details not covered by groups G06F3/00 - G06F13/00 and G06F21/00
- G06F1/16—Constructional details or arrangements
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01Q—ANTENNAS, i.e. RADIO AERIALS
- H01Q1/00—Details of, or arrangements associated with, antennas
- H01Q1/12—Supports; Mounting means
- H01Q1/22—Supports; Mounting means by structural association with other equipment or articles
- H01Q1/24—Supports; Mounting means by structural association with other equipment or articles with receiving set
- H01Q1/241—Supports; Mounting means by structural association with other equipment or articles with receiving set used in mobile communications, e.g. GSM
- H01Q1/242—Supports; Mounting means by structural association with other equipment or articles with receiving set used in mobile communications, e.g. GSM specially adapted for hand-held use
- H01Q1/243—Supports; Mounting means by structural association with other equipment or articles with receiving set used in mobile communications, e.g. GSM specially adapted for hand-held use with built-in antennas
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01Q—ANTENNAS, i.e. RADIO AERIALS
- H01Q1/00—Details of, or arrangements associated with, antennas
- H01Q1/36—Structural form of radiating elements, e.g. cone, spiral, umbrella; Particular materials used therewith
- H01Q1/38—Structural form of radiating elements, e.g. cone, spiral, umbrella; Particular materials used therewith formed by a conductive layer on an insulating support
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01Q—ANTENNAS, i.e. RADIO AERIALS
- H01Q1/00—Details of, or arrangements associated with, antennas
- H01Q1/40—Radiating elements coated with or embedded in protective material
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
- H01R4/04—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation using electrically conductive adhesives
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R43/00—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
- H01R43/20—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for assembling or disassembling contact members with insulating base, case or sleeve
- H01R43/24—Assembling by moulding on contact members
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- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K1/00—Printed circuits
- H05K1/02—Details
- H05K1/0284—Details of three-dimensional rigid printed circuit boards
-
- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K3/00—Apparatus or processes for manufacturing printed circuits
- H05K3/0011—Working of insulating substrates or insulating layers
- H05K3/0014—Shaping of the substrate, e.g. by moulding
-
- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K3/00—Apparatus or processes for manufacturing printed circuits
- H05K3/10—Apparatus or processes for manufacturing printed circuits in which conductive material is applied to the insulating support in such a manner as to form the desired conductive pattern
- H05K3/101—Apparatus or processes for manufacturing printed circuits in which conductive material is applied to the insulating support in such a manner as to form the desired conductive pattern by casting or moulding of conductive material
-
- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K3/00—Apparatus or processes for manufacturing printed circuits
- H05K3/40—Forming printed elements for providing electric connections to or between printed circuits
- H05K3/4007—Surface contacts, e.g. bumps
- H05K3/4015—Surface contacts, e.g. bumps using auxiliary conductive elements, e.g. pieces of metal foil, metallic spheres
-
- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K7/00—Constructional details common to different types of electric apparatus
- H05K7/02—Arrangements of circuit components or wiring on supporting structure
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
- B29C45/14065—Positioning or centering articles in the mould
- B29C2045/14114—Positioning or centering articles in the mould using an adhesive
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B29L2031/00—Other particular articles
- B29L2031/34—Electrical apparatus, e.g. sparking plugs or parts thereof
- B29L2031/3431—Telephones, Earphones
- B29L2031/3437—Cellular phones
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B29L2031/00—Other particular articles
- B29L2031/34—Electrical apparatus, e.g. sparking plugs or parts thereof
- B29L2031/3481—Housings or casings incorporating or embedding electric or electronic elements
-
- G—PHYSICS
- G06—COMPUTING; CALCULATING OR COUNTING
- G06F—ELECTRIC DIGITAL DATA PROCESSING
- G06F2203/00—Indexing scheme relating to G06F3/00 - G06F3/048
- G06F2203/041—Indexing scheme relating to G06F3/041 - G06F3/045
- G06F2203/04112—Electrode mesh in capacitive digitiser: electrode for touch sensing is formed of a mesh of very fine, normally metallic, interconnected lines that are almost invisible to see. This provides a quite large but transparent electrode surface, without need for ITO or similar transparent conductive material
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- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K2201/00—Indexing scheme relating to printed circuits covered by H05K1/00
- H05K2201/09—Shape and layout
- H05K2201/09009—Substrate related
- H05K2201/09118—Moulded substrate
-
- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K2201/00—Indexing scheme relating to printed circuits covered by H05K1/00
- H05K2201/09—Shape and layout
- H05K2201/09818—Shape or layout details not covered by a single group of H05K2201/09009 - H05K2201/09809
- H05K2201/0999—Circuit printed on or in housing, e.g. housing as PCB; Circuit printed on the case of a component; PCB affixed to housing
-
- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K2201/00—Indexing scheme relating to printed circuits covered by H05K1/00
- H05K2201/10—Details of components or other objects attached to or integrated in a printed circuit board
- H05K2201/10227—Other objects, e.g. metallic pieces
- H05K2201/1031—Surface mounted metallic connector elements
- H05K2201/10318—Surface mounted metallic pins
Definitions
- the present invention relates to an injection molded product for electrically connecting a contact pin and an electrode pattern, and a manufacturing method thereof.
- the present invention relates to an injection molded product that electrically connects a contact pin and an electrode pattern using a conductive adhesive and a method for manufacturing the same.
- insert molding as a method of electrically connecting a contact pin and an electrode pattern.
- an electrode pattern is provided on a base film, the electrode pattern and the contact pin are kept in contact, and the base film, the electrode pattern and the contact pin are covered with a molding resin and cooled and solidified, whereby the contact pin and the electrode pattern are formed. And electrically connect.
- outsert molding is another method for electrically connecting the contact pin and the electrode pattern.
- the base film and the electrode pattern are covered with molding resin so that a hole reaching the electrode pattern is formed, and a conductive adhesive is injected into the hole, and then a contact pin is inserted to insert the electrode pattern and the contact point. Electrically connect the pins.
- the electrical connection can be ensured as compared with the conventional insert molding, but the conductive adhesive must be injected before the contact pin is inserted into the hole.
- the solvent in the conductive adhesive is less likely to volatilize, and it takes time for the adhesive to dry and solidify. Swelling causes abnormal appearance.
- the hole diameter it is necessary to make the hole diameter larger than the tip needle diameter of the dispenser. However, if this hole diameter is increased, the difference in shrinkage between the base film and the molding resin around the hole A portion corresponding to the hole portion may appear to swell, and there is a risk of losing a sense of unity in appearance.
- the contact pin when the contact pin is inserted into the hole provided in the molding resin, the contact pin is directly pressed against the electrode pattern, so that pin marks may remain on the electrode pattern and the thin base film.
- the contact pin inserted into the hole breaks the electrode pattern, and the base film is cracked accordingly.
- the contact pin penetrates the electrode pattern and the base film.
- the diameter of the hole is made narrower than the contact pin so that the contact pin to be inserted does not wobble, and at the time of insertion, while applying ultrasonic vibration to the contact pin, while softening the molding resin of the hole contacting the periphery of the pin There was a problem that the process was complicated because it was necessary to press-fit.
- an object of the present invention is to provide an injection molded product that solves the conventional problems and has sufficient electrical connection between a contact pin and an electrode pattern, and a manufacturing method thereof.
- the injection molded product according to the first aspect of the present invention is: A base film, An electrode pattern formed on the base film; A conductive adhesive formed on the upper surface of the electrode pattern; A conductive contact pin in contact with the conductive adhesive and electrically connected to the electrode pattern through the conductive adhesive; The conductive adhesive and a molding resin that is injection-molded along the base film so as to embed a part of the contact pin.
- the conductive adhesive is a conductive adhesive composed of a conductive filler, a binder, and a solvent
- the binder is a thermoplastic resin
- the conductive adhesive is formed such that a portion in contact with the contact pin is raised in a mountain shape, from the upper surface of the electrode pattern to the top of the mountain of the conductive adhesive.
- the thickness is preferably in the range of 3 to 30% of the thickness of the molded resin.
- the contact pin may be a contact pin provided with a textured unevenness or an annular knurled groove on the pin surface.
- the contact pin may be a contact pin provided with a tapered portion that tapers toward a tip of the pin that contacts the conductive adhesive.
- the contact pin may be a contact pin having a pin tip portion that is a widened tip of the pin that contacts the conductive adhesive.
- the contact pin includes an annular knurled groove provided on the pin surface obliquely with respect to the pin axis direction, It may be a contact pin including an uneven portion provided on a circumferential portion of a pin tip that comes into contact with the conductive adhesive by extending the knurled groove.
- the method of manufacturing an injection molded product according to the second aspect of the present invention is as follows. Preparing an injection mold having a fixed mold and a movable mold which is movable toward and away from the fixed mold; Placing a base film provided with an electrode pattern and a conductive adhesive on the inner surface of the movable mold; and Disposing a conductive contact pin on the inner surface of the fixed mold; and Clamping the movable mold and the fixed mold so that the conductive adhesive on the movable mold side and the contact pin on the fixed mold side are in contact with each other; Injecting a molten resin into a cavity formed between the movable mold and the fixed mold on which the base film is placed, and bringing the molten resin into close contact with the surfaces of the conductive adhesive and the contact pins, Cooling and solidifying to form a molded resin; The fixed mold and the movable mold are opened, the base film, the electrode pattern formed on the base film, the conductive adhesive formed on the upper surface of the electrode pattern, and the
- the conductive adhesive is dried. Is preferred.
- a molten resin is injected into a cavity formed between the movable mold on which the base film is placed and the fixed mold, and the conductive adhesive and In the step of bringing the molten resin into close contact with the surface of each contact pin and cooling and solidifying it, it is preferable to use a conductive adhesive that deforms due to heat and pressure of the molten resin.
- the electronic device using the injection molded product according to the third aspect of the present invention uses the injection molded product according to the first aspect.
- the injection molded product and the manufacturing method according to the present invention since there is a conductive adhesive between the contact pin and the electrode pattern, the electrical connection between the contact pin and the electrode pattern can be reliably performed. Further, there is no process such as ultrasonic press-fitting as in outsert molding, and no drying time is required for volatilizing the solvent in the conductive adhesive, so that the manufacturing process and lead time can be reduced. As a result, it is possible to produce an injection molded product free from abnormal appearance that occurs due to dissolution or swelling of the base film due to the action of the solvent in the conductive adhesive at a low cost.
- the contact pin since no hole is provided in the molding resin, a portion corresponding to the hole portion does not swell due to a shrinkage difference between the base film and the molding resin in the peripheral portion of the hole, and a good appearance can be obtained.
- the contact pin since the contact pin is not inserted after molding, the pin pattern remains on the electrode pattern and the base film, the base film breaks, and in some cases, the contact pin penetrates the electrode pattern and the base film. Can be suppressed.
- FIG. 1 is a perspective view showing an injection molded product according to Embodiment 1.
- FIG. FIG. 2 is a cross-sectional view taken along the line AA of the injection molded product of FIG.
- FIG. 3 is an enlarged cross-sectional view illustrating a configuration of an injection molded product according to Embodiment 1.
- (A) is a top view which shows an example of the surface shape of the contact pin of the injection molded product which concerns on Embodiment 1
- (b) is a top view which shows another example of the surface shape of a contact pin.
- (A) is a top view which shows an example of the surface shape of the contact pin of the injection molded product which concerns on Embodiment 1
- (b) is a top view which shows another example of the surface shape of a contact pin.
- FIG. (A) is a top view which shows another example of the surface shape of the contact pin of the injection molded product which concerns on Embodiment 1
- (b) is a perspective view which shows another example of the front-end
- 3 is a cross-sectional view showing the thickness of the conductive adhesive of the injection molded product according to Embodiment 1.
- FIG. (A)-(d) is sectional drawing which shows each process of the manufacturing method of the injection molded product which concerns on Embodiment 2.
- FIG. It is the perspective view which showed other embodiment of the contact pin. It is the fragmentary top view which showed schematic structure of other embodiment of this invention.
- (A) is a cross-sectional view taken along line XX shown in FIG. 10
- (b) is a cross-sectional view taken along line YY shown in FIG. 10
- (c) corresponds to (a) in FIG. It is sectional drawing of other embodiment which did.
- FIG. 1 is a perspective view showing an injection molded product 10 according to Embodiment 1 of the present invention.
- FIG. 2 is a cross-sectional view taken along the line AA of the injection molded product 10 of FIG.
- An injection molded product 10 according to Embodiment 1 shown in FIGS. 1 and 2 includes a contact pin 2, a conductive adhesive 3, an electrode pattern 4, a base film 5 and a molding resin 7.
- FIG. 3 is an enlarged cross-sectional view showing the configuration of the injection molded product 10 according to the first embodiment.
- the base film 5, the electrode pattern 4 formed on the base film 5, the conductive adhesive 3 formed on the upper surface of the electrode pattern 4, and the conductive adhesive 3 are brought into contact with each other.
- Conductive contact pins 2 electrically connected to the electrode pattern 4 through the adhesive 3 and injection molding along the base film 5 so as to embed a part of the conductive adhesive 3 and the contact pins 2 Molded resin 7.
- FIG. 3 has shown the structure at the time of providing the design layer 6 as an example.
- the contact pin 2 made of a conductive material and the electrode pattern 4 are electrically connected via the conductive adhesive 3. Further, the molding resin 7 is in close contact with a part of the contact pin 2 and the surface of the conductive adhesive 3.
- the electrode pattern 4 may be a two-dimensional pattern. Alternatively, the electrode pattern 4 may be a three-dimensional pattern.
- the contact pin 2 and the electrode pattern 4 can be reliably electrically connected by the conductive adhesive 3. Further, since the molding resin 7 is in close contact with a part of the contact pin 2 and the surface of the conductive adhesive 3, the contact pin 2 can be firmly fixed as compared with the outsert molding.
- the portion corresponding to the hole portion does not swell due to the shrinkage difference between the base film 5 and the molding resin 7 around the hole. Can be obtained. Furthermore, since the contact pin 2 is not inserted after molding, the pin mark remains on the electrode pattern 4 and the base film 5, the base film 5 is cracked, and in some cases, the contact pin 2 causes the electrode pattern 4 and the base film 5 to break. Problems such as penetration can be suppressed.
- ⁇ Contact pin> As the contact pin 2, a material made of a conductive material, for example, a material such as copper, brass, phosphor bronze, iron, and stainless steel can be used.
- the outer diameter is preferably 0.2 to 2.0 mm. More preferably, it is ⁇ 0.4 to 1.0 mm.
- FIG. 4A is a plan view showing an example of the surface shape of the contact pin 2 of the injection molded product 10 according to Embodiment 1 of the present invention
- FIG. It is a top view which shows another example.
- the contact pin 2 may be a contact pin 11 provided with a satin-like unevenness on the pin surface.
- the contact pin 12 which provided the annular knurled groove in the pin surface may be sufficient.
- FIG. 5A is a plan view showing an example of the surface shape of the contact pin 2 of the injection molded product 10 according to Embodiment 1
- FIG. 5B is another example of the surface shape of the contact pin 2.
- FIG. 5 (a) the contact pin 13 which provided the taper part which tapers toward the pin front-end
- tip may be sufficient.
- the shape of the tip of the contact pin 14 includes a substantially cylindrical shape, a substantially disc shape, or a substantially inverted conical shape (not shown).
- the expanded pin tip portion is prevented from coming off from the molding resin 7, and the contact pin 14 is difficult to come off without providing irregularities or knurled grooves in the shape of the pin.
- FIG. 6A is a plan view showing another example of the surface shape of the contact pin 2 of the injection molded product 10 according to Embodiment 1 of the present invention
- FIG. 6B is the tip shape of the contact pin 2. It is a perspective view which shows another example of this.
- a contact pin 15 provided with a knurled groove oblique to the pin axial direction on the pin surface and an uneven portion on the circumferential portion of the pin tip. It may be.
- providing the groove on the pin surface makes it difficult for the pin to come off.
- the conductive adhesive 3 enters the uneven portion, and a reliable contact with the contact pin 2 can be formed.
- the conductive adhesive 3 is composed of a conductive filler, a binder, and a solvent.
- a conductive filler gold, silver, copper, aluminum, nickel, carbon, graphite, conductive powder in which a metal such as copper, nickel, silver or the like is plated on the surface of urethane particles or silica can be used.
- the binder includes polyester resins, acrylic resins, polyvinyl acetate vinyl copolymer resins, polyvinyl acetate vinyl maleic acid copolymer resins, rosin resins, rosin ester resins, petroleum resins, and other thermoplastic resins.
- a paste prepared by dissolving in a suitable solvent can be used, and may be applied by screen printing or a dispenser.
- FIG. 7 is a cross-sectional view showing the thickness d1 of the conductive adhesive 3 of the injection molded product 10 according to Embodiment 1 of the present invention.
- the conductive adhesive 3 is formed such that the portion that contacts the contact pin 2 is raised in a mountain shape, and the thickness d ⁇ b> 1 from the upper surface of the electrode pattern 4 to the top of the mountain of the conductive adhesive 3. Is preferably in the range of 3 to 30% of the wall thickness d2 of the molding resin 7. This is because if the thickness d1 of the conductive adhesive 3 is too thick, the flow resistance increases when the molten resin 8 is injected, and the conductive adhesive 3 flows into the molten resin 8. If the thickness d1 of the conductive adhesive 3 is too thin, the electrical connection between the contact pin 2 and the electrode pattern 4 becomes unstable.
- a hot-melt conductive adhesive in which each thermoplastic resin is melted by heat and the conductive filler is dispersed without using a solvent may be used. Since the hot-melt conductive adhesive does not contain a solvent, it is solid or semi-solid at normal temperature, so there is no need to dry the conductive adhesive, and it can be bonded by heating and melting at the time of injection of the molten resin 8 and cooling and solidifying. .
- the electrode pattern may be formed by screen printing or gravure printing using an electrode pattern ink. Moreover, you may form an electrode pattern with a metal vapor deposition film.
- the electrode pattern ink includes a conductive filler and a binder.
- the conductive filler gold, silver, copper, aluminum, nickel, carbon, graphite, or a powder obtained by plating copper, nickel, silver on a urethane particle or silica surface can be used.
- a thermoplastic resin such as a polyester resin, an acrylic resin, a vinyl acetate vinyl copolymer resin, a vinyl vinyl vinegar maleic acid copolymer resin, or a mixed resin is used for screen printing, gravure printing, flexographic printing. Ink that dissolves in a solvent compatible with each printing method can be used. Furthermore, epoxy, urethane, and acrylic thermosetting resins and UV curable resins can be used as binders.
- the electrode pattern layer may be a metal vapor deposition film such as aluminum or copper, or may be formed by etching aluminum or copper foil laminated on a base film.
- ⁇ Base film> As the material of the base film 5, for example, polyester resin, acrylic resin, polycarbonate resin, PBT resin, styrene resin, ABS resin film, a multilayer film of acrylic resin and ABS resin, a multilayer film of acrylic resin and polycarbonate resin, etc. are used. it can.
- the design layer 6 may be provided to decorate the appearance of the injection molded product 10.
- a thermosetting resin such as a urethane resin, an acrylic urethane resin, a polyester urethane resin, an acrylic resin, a vinyl chloride vinyl acetate copolymer resin, a UV curable resin, or a thermoplastic resin is used as a binder. Ink can be used.
- layers such as an insulating layer, a shield layer, a release layer, an adhesive layer, and an anchor layer may be provided.
- the molding resin 7 may be transparent, translucent, or opaque. Further, the molding resin 7 may be colored or not colored. Examples of the resin of the molding resin 7 include general-purpose resins such as polystyrene resin, polyolefin resin, ABS resin, AS resin, or AN resin. As another resin of the molding resin 7, polycarbonate resin, polyacetal resin, acrylic resin, polyethylene terephthalate resin, polybutylene terephthalate resin, or super engineering resin (polysulfone resin, polyphenylene sulfide resin, polyphenylene oxide resin) Resin, polyacrylate resin) can also be used. As another resin of the molding resin 7, a composite resin to which a reinforcing material such as glass fiber or inorganic filler is added can also be used.
- FIGS. 8 (a) to 8 (d) are cross-sectional views showing respective steps of the method of manufacturing the injection molded product 10 according to Embodiment 2 of the present invention.
- An injection mold having a fixed mold 22 and a movable mold 21 that is movable toward and away from the fixed mold 22 is prepared (FIG. 8A).
- the base film 5 provided with the electrode pattern 4 and the conductive adhesive 3 is placed on the inner surface of the movable mold 21 (FIG. 8A).
- the conductive adhesive 3 is preferably dried.
- the conductive adhesive 3 is a conductive adhesive composed of a conductive filler, a binder, and a solvent, and it is preferable to use a conductive adhesive whose binder is a thermoplastic resin. Furthermore, the thickness d1 of the conductive adhesive 3 is preferably in the range of 3 to 30% of the thickness d2 of the molding resin 7. A hot melt conductive adhesive may be used. A design layer 6 for decorating the appearance of the injection molded product 10 may be provided on the lower side of the base film 5, and there may be an insulating layer, a shield layer, a release layer, an anchor layer, and the like. (3) The conductive contact pin 2 is disposed on the inner surface of the fixed mold 22 (FIG. 8A).
- the contact pin 2 may be a contact pin 11 having a satin-like unevenness on the pin surface (FIG. 4A), or may be a contact pin 12 having an annular knurled groove on the pin surface. Good (FIG. 4B). Further, a contact pin 13 provided with a taper portion that tapers toward the tip of the pin at the tip of the pin or a contact pin 14 having a pin tip that is an expanded pin tip may be used (FIG. 5A, FIG. 5). (B)).
- annular knurled groove provided obliquely with respect to the pin axis direction on the pin surface, and a concavo-convex portion provided on the circumferential portion of the pin tip contacting the conductive adhesive 3 by extending the knurled groove;
- a contact pin 15 including the above may be used (FIG. 6).
- the movable mold 21 and the fixed mold 22 are clamped so that the conductive adhesive 3 of the movable mold 21 and the contact pins 2 arranged on the inner surface of the fixed mold 22 are in contact (FIG. 8B). .
- the tip of the contact pin 2 is inserted while strongly pressing the surface of the conductive adhesive 3, so that compressive stress remains in the conductive adhesive 3 immediately below the pin, and the conductive adhesive 3 is attached to the contact pin 2. It will be pushed up to the surroundings.
- the molten resin 8 is injected into the cavity formed between the movable mold 21 on which the base film 5 is placed and the fixed mold 22, and the molten resin 8 is applied to the surfaces of the conductive adhesive 3 and the contact pin 2. Are closely adhered, cooled and solidified to form a molded resin 7 (FIG. 8C).
- the conductive adhesive 3 When the molten resin 8 is injected, the conductive adhesive 3 is softened and deformed by the heat and pressure of the molten resin 8, so that the above-described compressive stress is relieved. And since the conductive adhesive 3 pushed up around the contact pin 2 adheres so that the periphery of the front-end
- the movable mold 21 and the fixed mold 22 are opened, the base film 5, the electrode pattern 4 formed on the base film 5, the conductive adhesive 3 formed on the upper surface of the electrode pattern 4, and the conductive
- the base film 5 is embedded so as to embed a part of the contact pin 2 in contact with the adhesive 3 and electrically connected to the electrode pattern 4 via the conductive adhesive 3, the conductive adhesive 3, and the contact pin 2.
- an injection molded product 10 made of the molding resin 7 injection molded along is taken out (FIG. 8D).
- the injection molded product 10 can be obtained as described above.
- the conductive adhesive 3 is present between the contact pin 2 and the electrode pattern 4, the electrical connection between the contact pin 2 and the electrode pattern 4 can be reliably performed. Furthermore, since the molding resin 7 is in close contact with the surfaces of the conductive adhesive 3 and the contact pin 2 as compared with the outsert molding, the contact pin 2 can be more firmly fixed.
- the contact pin 2 since the contact pin 2 is not press-fitted, the pin mark remains on the electrode pattern 4 and the base film 5, the base film 5 is broken, and in some cases, the contact pin 2 penetrates the electrode pattern 4 and the base film 5. The problem of ending up can be suppressed.
- the conductive adhesive 3 is dried in step (2) of the manufacturing method, the conductive adhesive 3 is provided on the base film 5 when the molten resin 8 is injected in step (5) of the manufacturing method. Since it is adhered to the formed electrode pattern 4, it is not flowed by the molten resin 8. As a result, even when the contact pin 2 is inserted simultaneously with the injection molding, the electrical connection between the contact pin 2 and the electrode pattern 4 can be reliably performed by the conductive adhesive 3.
- the conductive adhesive 3 is a conductive adhesive that is deformed by the heat and pressure of the molten resin 8, for example, a conductive adhesive composed of a conductive filler, a binder, and a solvent.
- a conductive adhesive or hot melt conductive adhesive whose binder is a thermoplastic resin
- the conductive adhesive 3 solidified upon injection of the molten resin 8 is deformed by the heat and pressure of the molten resin 8, and the conductive adhesive 3 is adhered so as to cover the periphery of the tip of the contact pin 2.
- the degree of adhesion between the conductive adhesive 3 and the contact pin 2 is increased, and the conductivity is improved.
- the contact pin 11 is provided with a textured unevenness
- the contact pin 12 is provided with an annular knurled groove
- the contact pin 13 is provided with a taper portion
- the pin tip portion is formed by expanding the pin tip.
- the contact pin 14 and the contact pin 15 provided with an oblique knurled groove can be used.
- the conductive adhesive 3 enters the groove on the pin surface and the tip portion or the concavo-convex portion, so that a more reliable contact can be formed.
- the molding resin 7 enters the irregularities and grooves on the pin surface, or the pin tip is an enlarged pin tip, the contact pin 2 is less likely to be removed from the molding resin 7.
- Examples of the electronic device using the injection molded product 10 include a smartphone, a tablet PC, a portable music player, a mobile phone, an electronic book reader, and an IC recorder.
- the contact pin 2 has an elongated cylindrical shape. However, one end of the contact pin 2 is in contact with the conductive adhesive formed on the upper surface of the electrode pattern, and the electrode pattern is connected to the electrode pattern via the conductive adhesive. Other shapes such as a flat plate shape may be used as long as they are electrically connected and have conductivity.
- the contact pin 35 has a flat plate shape extending in a band shape, and one circular opening 32 is formed at the center of each end.
- the material of the contact pin 35 is made of a conductive material like the contact pin 2, and preferably has a plate thickness t of 0.05 mm to 2 mm and a plate width w of 1 mm to 8 mm.
- the plate thickness t is preferably 0.15 mm to 1 mm
- the plate width w is preferably 1.5 mm to 4 mm, for example. If the plate thickness is too thin, undesired deformations such as bending of the contact pin 35 due to resin pressure during injection molding of the molding resin 7 are likely to occur, and if the plate thickness is too thick, the contact pin 35 arrangement portion on the front surface of the molding resin 7 Distortion occurs, and defects in appearance design tend to occur. If the plate thickness is too thick, it becomes difficult to bend when there is a secondary process of bending the tip of the contact pin. If the plate width is too narrow, the same phenomenon as when the plate thickness is too thin is likely to occur.
- size of the contact pin 35 is suitably selected according to the goods applied to the injection molded products 40, such as a smart phone and a tablet PC, and the component structure inside goods.
- the injection molded product 40 since the injection molded product 40 has the same basic configuration as the injection molded product 10, the injection molded product 40 is different from the injection molded product 10 in configuration.
- the contact pin 2 In the injection molded product 10, the contact pin 2 has a cylindrical shape.
- the contact pin 35 has an elongated flat plate shape, and one end is brought into contact with a conductive adhesive. An opening 32 at one end is embedded in the molding resin 7, and the other end is exposed from the molding resin 7, and is fixed so as to extend in a band shape from the base film 5 in the orthogonal direction.
- the exposed contact pin 35 is formed with a support portion 30 that is a part of the molding resin 7 that rises integrally from the upper surface of the molding resin 7 to a predetermined height along the outer peripheral surface of the contact pin 35.
- the support part 30 constitutes a reinforcing member.
- a flat rib 31 is formed as a part of the molding resin 7 on the rising surface on the long side of the support portion 30, and the rib 31 is orthogonal to the rising surface on the long side of the support portion 30.
- the reinforcing member is formed integrally with the support portion 30, and the support portion 30 and the rib 31 are formed so as to rise integrally from the upper surface of the molding resin 7. Since the opening 32 of the contact pin 35 embedded in the molding resin 7 is filled with the molding resin 7, the opening 32 is provided so that the contact pin 35 is not easily pulled out even when the contact pin 35 is pulled. Also, it is possible to make it difficult to penetrate the surface side of the injection molded product 40.
- the opening 32 is formed at both ends of the contact pin 35, but the opening 32 may not be formed at the end portion exposed from the molding resin 7.
- both ends of the contact pin 35 may be embedded in the molding resin 7, and the injection molded product 40 is manufactured. Becomes easy.
- FIG. 11A if one opening 32 is added to the portion covered with the support portion 30 and two openings 32 are formed in the molding resin 7 so as to be aligned in the axial direction, the contact pin 35 is fixed more firmly. can do.
- the support portion 30 is formed in an annular shape along the outer peripheral surface of the contact pin 35 in a plan view. However, if the support portion 30 has a shape that increases the degree of fixing of the contact pin 35, the support portion 30 may have a single shape in a plan view. There may be a portion where the support portion 30 is not present.
- the support portion 30 and the rib 31 are configured, the strength of the contact pin 35 in the horizontal direction and the difficulty of bending deformation are improved, and it can be fixed to the molding resin 7 in a more stable state.
- the contact pin 35 may be erected while having one end embedded in the molding resin 7 without forming the support portion 30 and the rib 31.
- the rib 31 may not be configured, and only the support portion 30 may be configured.
- the contact pin 35 has openings 32 at both ends thereof, but may have other shapes.
- the contact pin 36 has a flat plate shape extending in a band shape, and instead of the opening 32, the contact pin 36 has a triangular shape so that apexes are directed inward at both ends of the two long sides.
- a notch 33 is formed.
- the contact pin 37 has a flat plate shape extending in a band shape, and instead of the opening 32, a trapezoidal shape is formed so that the width increases inward toward the center of both sides.
- a cutout 34 having a shape is formed.
- Notches 33 and 34 at one end are embedded in the molding resin 7 so that the contact pins 36 and 37 are not easily removed from the molding resin 7.
- the openings and notches are not formed only at both ends of the contact pin, but three or more openings and notches may be formed continuously from one end to the other end, and the notches formed on the long side In this case, it may be formed only on one side instead of being formed on both sides.
- the number of openings and notches is not limited. Openings 32 and notches 33 and 34 are formed in at least portions of the contact pins 35, 36 and 37 embedded in the molding resin 7.
- the shape, size, and position of the opening and notch if the shape, size, and position are such that it is difficult to pull out even if the contact pin is pulled, and it is difficult to penetrate the surface side of the injection molded product even if the contact pin is pressed.
- Other shapes, sizes and positions other than those described above may be used. Depending on the required pull-out strength, these contact pins may not have any openings or notches.
- the contact pin 35 has a flat plate shape, unlike the cylindrical shape, the component has directionality and a large area when viewed from the axial direction. It becomes easy. Further, in the contact pin 35, since the contact area with the conductive adhesive is increased as compared with the cylindrical contact pin 2, the conduction between the electrode pattern 4 and the contact pin 35 can be further stabilized, and a larger current can be obtained. Can pass through. Furthermore, since it is a flat plate, it is easy to form an opening and a notch, and the pull-out strength of the contact pin 35 can be easily improved.
- the injection molded product and the manufacturing method thereof according to the present invention are useful when the contact pin is electrically connected to the electrode pattern.
- the electrode pattern is useful, for example, when an electrical connection is made with an electrode pattern such as an antenna used in portable terminals in recent years or an electrostatic capacitively coupled power transmission pattern with a contact pin.
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Abstract
Description
ベースフィルムと、
前記ベースフィルムの上に形成された電極パターンと、
前記電極パターンの上面に形成された導電接着剤と、
前記導電接着剤と接触し、前記導電接着剤を介して前記電極パターンと電気的に接続された導電性を有する接点ピンと、
前記導電接着剤と、前記接点ピンの一部を埋設するように、前記ベースフィルムに沿って射出成形された成形樹脂と、を備える。
前記ローレット溝が延長形成されることにより前記導電接着剤と接触するピン先端の円周部に設けられた凹凸部と、を含む接点ピンであってもよい。
固定型と前記固定型に対して接離自在な可動型とを備えた射出成形金型を用意するステップと、
前記可動型の内面に、電極パターン及び導電接着剤が設けられたベースフィルムを載置するステップと、
前記固定型の内面に、導電性を有する接点ピンを配置するステップと、
前記可動型側の前記導電接着剤と前記固定型側の前記接点ピンとが接触するように、前記可動型と前記固定型とを型締めするステップと、
前記ベースフィルムが載置された前記可動型と前記固定型との間に形成される空洞部に溶融樹脂を射出し、前記導電接着剤と前記接点ピンそれぞれの表面に前記溶融樹脂を密着させ、冷却・固化して成形樹脂を形成するステップと、
前記固定型と前記可動型を型開きし、前記ベースフィルムと、前記ベースフィルムの上に形成された前記電極パターンと、前記電極パターンの上面に形成された前記導電接着剤と、前記導電接着剤と接触し、前記導電接着剤を介して前記電極パターンと電気的に接続された前記接点ピンと、前記導電接着剤と、前記接点ピンの一部を埋設するように、前記ベースフィルムに沿って射出成形された前記成形樹脂と、からなる射出成形品を取り出すステップと、を含む。
<射出成形品>
図1は、本発明の実施の形態1に係る射出成形品10を示す斜視図である。図2は、図1の射出成形品10のA-A断面図である。図1及び図2に示す実施の形態1に係る射出成形品10は、接点ピン2、導電接着剤3、電極パターン4、ベースフィルム5及び成形樹脂7を備える。また、上記構成に加え、絶縁層、シールド層、表面を傷から保護する剥離層、意匠を表現する意匠層、成形樹脂7との接着性を向上させるアンカー層等があってもよい。
<接点ピン>
接点ピン2としては、導電性を有する材料からなるもの、例えば、銅、真鍮、リン青銅、鉄、ステンレス等の材料を使用することができる。外径は、φ0.2~2.0mmが好ましい。より好ましくはφ0.4~1.0mmである。
導電接着剤3は、導電フィラー、バインダー及び溶剤から構成されている。導電フィラーとしては、金、銀、銅、アルミニューム、ニッケル、カーボン、グラファイト、あるいは、ウレタン粒子やシリカ表面に銅、ニッケル、銀等の金属をメッキした導電性粉末等が使用できる。また、バインダーとしては、ポリエステル系樹脂、アクリル系樹脂、塩ビ酢ビ共重合樹脂、塩ビ酢ビマレイン酸共重合樹脂やロジン系、ロジンエステル系、石油樹脂等の各熱可塑性樹脂があり、前記樹脂を適合する溶剤で溶解しペースト化したものが使用でき、スクリーン印刷あるいはディスペンサーで塗布してもよい。
電極パターンは、電極パターン用インキを用いてスクリーン印刷、またはグラビア印刷で形成してもよい。また、電極パターンは、金属蒸着膜で形成してもよい。
<電極パターン用インキ>
電極パターン用インキは、導電フィラーと、バインダーとを含む。導電フィラーとしては、金、銀、銅、アルミニューム、ニッケル、カーボン、グラファイト、あるいは、ウレタン粒子やシリカ表面に銅、ニッケル、銀メッキした粉末等が使用できる。また、バインダーとしては、ポリエステル系樹脂、アクリル系樹脂、塩ビ酢ビ共重合樹脂、塩ビ酢ビマレイン酸共重合樹脂の単独、あるいは、混合樹脂等の熱可塑性樹脂を、スクリーン印刷、グラビア印刷、フレキソ印刷等の各印刷方式に適合する溶剤で溶解するインキが使用できる。さらに、エポキシ系、ウレタン系、アクリル系の熱硬化型樹脂やUV硬化型樹脂をバインダーとして使用できる。
<金属蒸着膜>
電極パターン層は、アルミあるいは銅等の金属蒸着膜であってもよいし、ベースフィルムにラミネートしたアルミあるいは銅箔をエッチングすることにより形成されたものでもよい。
ベースフィルム5の材質としては、例えば、ポリエステル樹脂、アクリル樹脂、ポリカーボネート樹脂、PBT樹脂、スチレン樹脂、ABS樹脂フィルム、及びアクリル樹脂とABS樹脂の多層フィルム、アクリル樹脂とポリカーボネート樹脂の多層フィルム等が使用できる。
意匠層6は、射出成形品10の外観を装飾するために設けてもよい。また、意匠層6の材料としては、例えば、ウレタン樹脂、アクリルウレタン樹脂、ポリエステルウレタン樹脂、アクリル系樹脂、塩ビ酢ビ共重合樹脂等の熱硬化樹脂、UV硬化樹脂、熱可塑性樹脂をバインダーとしたインキが使用できる。なお、意匠層6の他に絶縁層、シールド層、剥離層、接着層、アンカー層等の層を設けてもよい。
成形樹脂7は、透明、半透明、不透明のいずれでもよい。また、成形樹脂7は、着色されていても、着色されていなくてもよい。成形樹脂7の樹脂としては、ポリスチレン系樹脂、ポリオレフィン系樹脂、ABS樹脂、AS樹脂、もしくは、AN樹脂などの汎用樹脂を挙げることができる。また、成形樹脂7の別の樹脂として、ポリカーボネート系樹脂、ポリアセタール系樹脂、アクリル系樹脂、ポリエチレンテレフタレート系樹脂、ポリブチレンテレフタレート樹脂、または、スーパーエンジニアリング樹脂(ポリスルホン樹脂、ポリフェニレンサルファイド系樹脂、ポリフェニレンオキシド系樹脂、ポリアクリレート樹脂)を使用することもできる。成形樹脂7のさらに別の樹脂として、ガラス繊維若しくは無機フィラーなどの補強材を添加した複合樹脂も使用できる。
次に、実施の形態2に係る射出成形品10の製造方法について図8(a)~(d)を用いて説明する。図8(a)~(d)は、本発明の実施の形態2に係る射出成形品10の製造方法の各工程を示す断面図である。
(1)固定型22と固定型22に対して接離自在な可動型21とを備えた射出成形用金型を用意する(図8(a))。
(2)可動型21の内面に、電極パターン4及び導電接着剤3が設けられたベースフィルム5を載置する(図8(a))。導電接着剤3は、乾燥させるのが好ましい。また、導電接着剤3は、導電フィラー、バインダー及び溶剤から構成されている導電接着剤であって、バインダーが熱可塑性樹脂である導電接着剤を用いるのが好ましい。さらに、導電接着剤3の厚さd1は、成形樹脂7の肉厚d2の3~30%の範囲であるのが好ましい。なお、ホットメルト導電接着剤を使用してもよい。ベースフィルム5の下側には射出成形品10の外観を装飾するための意匠層6を設けてもよく、他に絶縁層、シールド層、剥離層、アンカー層等があってもよい。
(3)固定型22の内面に、導電性を有する接点ピン2を配置する(図8(a))。接点ピン2は、ピン表面に梨地状の凹凸が設けられた接点ピン11を用いてもよく(図4(a))、ピン表面に環状のローレット溝が設けられた接点ピン12を用いてもよい(図4(b))。また、ピン先端部にピン先端に向かって先細りするテーパ部を設けた接点ピン13あるいはピン先端を拡開したピン先端部を有する接点ピン14を用いてもよい(図5(a)、図5(b))。さらに、ピン表面にピン軸方向に対し斜めに設けられた環状のローレット溝と、ローレット溝が延長形成されることにより導電接着剤3と接触するピン先端の円周部に設けられた凹凸部とを含む接点ピン15を用いてもよい(図6)。
(4)可動型21の導電接着剤3と固定型22の内面に配置された接点ピン2とが接触するように、可動型21と固定型22とを型締めする(図8(b))。型締め時に、接点ピン2の先端部は、導電接着剤3の表面を強く押しながら差し込まれるのでピン直下の導電接着剤3中には圧縮応力が残るとともに、導電接着剤3が接点ピン2の周囲に押し上げられた状態になる。
(5)ベースフィルム5が載置された可動型21と固定型22との間に形成される空洞部に溶融樹脂8を射出し、導電接着剤3と接点ピン2それぞれの表面に溶融樹脂8を密着させ、冷却・固化して成形樹脂7を形成する(図8(c))。溶融樹脂8の射出時に、溶融樹脂8の熱と圧力により導電接着剤3が軟化し、変形するので上述した圧縮応力は緩和される。そして、接点ピン2の周囲に押し上げられた導電接着剤3は、接点ピン2の先端部周辺を覆うように接着するため、導電接着剤3と接点ピン2との密着度が上がる。
(6)可動型21と固定型22を型開きし、ベースフィルム5と、ベースフィルム5の上に形成された電極パターン4と、電極パターン4の上面に形成された導電接着剤3と、導電接着剤3と接触し、導電接着剤3を介して電極パターン4と電気的に接続された接点ピン2と、導電接着剤3と、接点ピン2の一部を埋設するように、ベースフィルム5に沿って射出成形された成形樹脂7と、からなる射出成形品10を取り出す(図8(d))。
以上によって、射出成形品10を得ることができる。
図9の(a)を参照して、接点ピン35は、帯状に延びる平板形状からなり、両端の中央に円形の開口32が1箇所ずつ形成されている。接点ピン35の材質は、接点ピン2と同様に導電性材料からなり、好ましくは、板厚tは0.05mm~2mm、板幅wは1mm~8mmのものが例えば使用される。更に、板厚tは好ましくは0.15mm~1mm、板幅wは好ましくは1.5mm~4mmが例えば使用される。板厚が薄すぎると成形樹脂7の射出成形時に樹脂圧により接点ピン35が曲がるなど望まない変形が起こり易くなり、板厚が厚すぎると成形樹脂7の表側の面の接点ピン35の配置部分にひずみが生じ、外観意匠上の欠点が生じやすくなる。板厚が厚すぎると、接点ピンの先端を曲げる2次加工がある場合には、曲げにくくなってしまう。板幅は、狭すぎると板厚が薄すぎるときと同じ現象が起こり易くなるところ、広すぎても成形樹脂7の射出成形時の樹脂圧が大きくかかることとなり、樹脂圧による変形が生じ易くなる。接点ピン35の大きさは、スマートフォンやタブレットPCなど射出成形品40に適用される商品や商品内部の部品構成に応じて適宜選定される。
3 導電接着剤
4 電極パターン
5 ベースフィルム
6 意匠層
7 成形樹脂
8 溶融樹脂
10、40 射出成形品
11 梨地状の凹凸を設けた接点ピン
12 環状のローレット溝を設けた接点ピン
13 テーパ部を設けた接点ピン
14 ピン先端を拡開したピン先端部を有する接点ピン
15 斜めのローレット溝を設けた接点ピン
21 可動型(CAV)
22 固定型(COR)
30 支持部
31 リブ
32 開口
33、34 切欠き
Claims (14)
- ベースフィルムと、
前記ベースフィルムの上に形成された電極パターンと、
前記電極パターンの上面に形成された導電接着剤と、
前記導電接着剤と接触し、前記導電接着剤を介して前記電極パターンと電気的に接続された導電性を有する接点ピンと、
前記導電接着剤と、前記接点ピンの一部を埋設するように、前記ベースフィルムに沿って射出成形された成形樹脂と、を備えた射出成形品。 - 前記導電接着剤は、導電フィラー、バインダー及び溶剤から構成されている導電接着剤であって、前記バインダーが熱可塑性樹脂である、請求項1に記載の射出成形品。
- 前記導電接着剤は、前記接点ピンと接触する部分が山形状に盛り上がるように形成されており、前記電極パターン上面から前記導電接着剤の山の頂上までの厚さは、成形樹脂の肉厚の3~30%の範囲である、請求項1に記載の射出成形品。
- 前記接点ピンは、ピン表面に梨地状の凹凸が設けられた、請求項1に記載の射出成形品。
- 前記接点ピンは、ピン表面に環状のローレット溝が設けられた、請求項1に記載の射出成形品。
- 前記接点ピンは、前記導電接着剤と接触するピン先端にテーパ部が設けられた、請求項1に記載の射出成形品。
- 前記接点ピンは、前記導電接着剤と接触するピン先端を拡開したピン先端部を有する、請求項1に記載の射出成形品。
- 前記接点ピンは、ピン表面にピン軸方向に対し斜めに設けられた環状のローレット溝と、
前記ローレット溝が延長形成されることにより前記導電接着剤と接触するピン先端の円周部に設けられた凹凸部と、
を含む、請求項1に記載の射出成形品。 - 前記接点ピンは平板形状を有し、前記成形樹脂に埋設された部分に開口又は切欠きが形成された、請求項1から3のいずれか1項に記載の射出成形品。
- 前記接点ピンの外周面に沿って、前記成形樹脂の上面から一体的に立ち上がるように形成された補強部材を更に備えた、請求項1から9のいずれか1項に記載の射出成形品。
- 固定型と前記固定型に対して接離自在な可動型とを備えた射出成形金型を用意するステップと、
前記可動型の内面に、電極パターン及び導電接着剤が設けられたベースフィルムを載置するステップと、
前記固定型の内面に、導電性を有する接点ピンを配置するステップと、
前記可動型側の前記導電接着剤と前記固定型側の前記接点ピンとが接触するように、前記可動型と前記固定型とを型締めするステップと、
前記ベースフィルムが載置された前記可動型と前記固定型との間に形成される空洞部に溶融樹脂を射出し、前記導電接着剤と前記接点ピンそれぞれの表面に前記溶融樹脂を密着させ、冷却・固化して成形樹脂を形成するステップと、
前記固定型と前記可動型を型開きし、前記ベースフィルムと、前記ベースフィルムの上に形成された前記電極パターンと、前記電極パターンの上面に形成された前記導電接着剤と、前記導電接着剤と接触し、前記導電接着剤を介して前記電極パターンと電気的に接続された前記接点ピンと、前記導電接着剤と、前記接点ピンの一部を埋設するように、前記ベースフィルムに沿って射出成形された前記成形樹脂と、からなる射出成形品を取り出すステップと、
を含む、射出成形品の製造方法。 - 前記可動型の内面に前記電極パターン及び前記導電接着剤が設けられた前記ベースフィルムを載置するステップにおいて、前記導電接着剤を乾燥させることを特徴とする、請求項11に記載の射出成形品の製造方法。
- 前記ベースフィルムが載置された前記可動型と前記固定型との間に形成される空洞部に前記溶融樹脂を射出し、前記導電接着剤と前記接点ピンそれぞれの表面に前記溶融樹脂を密着させて冷却・固化させるステップにおいて、前記導電接着剤が前記溶融樹脂の熱と圧力により変形する導電接着剤を用いることを特徴とする、請求項11に記載の射出成形品の製造方法。
- 請求項1から10のいずれか1項に記載の前記射出成形品を用いた電子機器。
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WO2015025646A1 (ja) * | 2013-08-21 | 2015-02-26 | 日本写真印刷株式会社 | 複合成形品及びその製造方法 |
JP2015039807A (ja) * | 2013-08-21 | 2015-03-02 | 日本写真印刷株式会社 | 複合成形品及びその製造方法 |
US9444153B2 (en) | 2013-08-21 | 2016-09-13 | Nissha Printing Co., Ltd. | Composite molding and method of manufacturing the same |
JP2017217871A (ja) * | 2016-06-09 | 2017-12-14 | Nissha株式会社 | 電極パターン一体化成形品及びその製造方法 |
US10383234B2 (en) | 2016-06-09 | 2019-08-13 | Nissha Co., Ltd. | Molding with integrated electrode pattern and method for manufacturing same |
WO2021075125A1 (ja) * | 2019-10-18 | 2021-04-22 | Nissha株式会社 | 成形品、電気製品及び成形品の製造方法 |
JP2021068755A (ja) * | 2019-10-18 | 2021-04-30 | Nissha株式会社 | 成形品、電気製品及び成形品の製造方法 |
JP7128791B2 (ja) | 2019-10-18 | 2022-08-31 | Nissha株式会社 | 成形品、電気製品及び成形品の製造方法 |
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US9448678B2 (en) | 2016-09-20 |
CN104349883B (zh) | 2016-06-29 |
KR20150020580A (ko) | 2015-02-26 |
WO2013180142A1 (ja) | 2013-12-05 |
TW201404569A (zh) | 2014-02-01 |
US9256334B2 (en) | 2016-02-09 |
WO2013180143A1 (ja) | 2013-12-05 |
US20150138139A1 (en) | 2015-05-21 |
KR101561179B1 (ko) | 2015-10-15 |
KR101691136B1 (ko) | 2016-12-29 |
KR20150004429A (ko) | 2015-01-12 |
KR101686892B1 (ko) | 2016-12-15 |
CN104349883A (zh) | 2015-02-11 |
TWI571376B (zh) | 2017-02-21 |
US20150103503A1 (en) | 2015-04-16 |
JP5546696B2 (ja) | 2014-07-09 |
KR20150020579A (ko) | 2015-02-26 |
JPWO2013180132A1 (ja) | 2016-01-21 |
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