U.S. patent application number 10/176213 was filed with the patent office on 2002-10-24 for integrally molded remote entry transmitter.
This patent application is currently assigned to Lear Automotive Dearborn, Inc.. Invention is credited to Krupp, Eric, McConnell, John E., Nantz, John.
Application Number | 20020154050 10/176213 |
Document ID | / |
Family ID | 22886587 |
Filed Date | 2002-10-24 |
United States Patent
Application |
20020154050 |
Kind Code |
A1 |
Krupp, Eric ; et
al. |
October 24, 2002 |
Integrally molded remote entry transmitter
Abstract
Remote entry transmitters are formed to have a housing element
made by a two-shot molding technique. A plateable and a
non-plateable plastic are molded in the two-shot molding technique.
Circuit trace material is then plated onto the plateable material.
This results in a reduction in the number of separate parts for the
transmitter. In addition, the antenna is positioned to be
non-parallel to the main circuit board. This results in packaging
efficiencies and improvements. Preferably, the antenna may be
plated onto an inner side wall of the housing when the two-shot
molding technique occurs. Alternatively, the antenna may be
provided as a separate board.
Inventors: |
Krupp, Eric; (Canton,
MI) ; Nantz, John; (Brighton, MI) ; McConnell,
John E.; (Ann Arbor, MI) |
Correspondence
Address: |
Jeremy J. Curcuri
Brooks & Kushman P.C.
22nd Floor
1000 Town Center
Southfield
MI
48075-1351
US
|
Assignee: |
Lear Automotive Dearborn,
Inc.
Southfield
MI
|
Family ID: |
22886587 |
Appl. No.: |
10/176213 |
Filed: |
June 20, 2002 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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10176213 |
Jun 20, 2002 |
|
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|
09235701 |
Jan 22, 1999 |
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6433728 |
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Current U.S.
Class: |
341/173 |
Current CPC
Class: |
H01Q 1/242 20130101;
H05K 3/182 20130101; G07C 9/00944 20130101; H04B 1/3877 20130101;
H04B 1/034 20130101; H05K 1/0284 20130101; H01Q 1/3241
20130101 |
Class at
Publication: |
341/173 |
International
Class: |
H04L 017/02; G08C
019/12 |
Claims
What is claimed is:
1. A method of forming a remote entry transmitter comprising: 1)
providing a housing by utilizing a molding technique molding a
non-plateable and a plateable plastic together; 2) then plating
conductive material on the plateable areas to form circuit traces;
and 3) inserting circuit elements into said housing for
communicating with said circuit traces, said circuit elements
including a transmitter for a remote entry system.
2. A method as set forth in claim 1, wherein said non-plateable
materials also form a decorative outer surface for said remote
entry transmitter.
3. A method as set forth in claim 1, wherein said housing element
is a cover of a remote entry transmitter.
4. A method as set forth in claim 1, wherein an antenna is inserted
into said remote entry transmitter, said antenna being disposed at
a non-parallel angle relative to said circuit traces.
5. A method as set forth in claim 4, wherein said antenna is plated
on plateable plastic during the plating of the conductive material
as set forth in step 2.
6. A remote entry transmitter housing comprising: a housing; a
battery and a transmitter for transmitting a signal, and received
in said housing, a main circuit being disposed generally in a first
plane, and an antenna communicating with said transmitter, said
antenna being disposed generally non-parallel to said plane of said
main circuit.
7. A housing as recited in claim 6, wherein said housing having a
side wall, and said antenna being disposed on an inner portion of
said side wall.
8. A housing as recited in claim 7, wherein said antenna is molded
onto an inner side of said sidewall.
9. A housing as recited in claim 8, wherein said main circuit is
also molded onto said housing along with said antenna.
10. A housing as recited in claim 6, wherein said antenna is
included on a separate circuit board which is attached to said main
circuit.
11. A remote entry transmitter housing comprising: a first and
second housing member, with one of said first and second housing
members being formed of a two-shot molding technique, such that
circuit traces within said remote entry transmitter are formed by
plating onto a plateable plastic deposited into said housing by
said two-shot molding technique.
12. A housing as set forth in claim 11, wherein a decorative outer
surface of said at least one housing is formed by non-plateable
plastic during the two-shot molding technique.
13. A housing as set forth in claim 11, wherein said one housing
has an inner side wall, and an antenna for said transmitter is
adhered to said inner side wall.
14. A housing as recited in claim 13, wherein said antenna is
molded onto said inner side wall along with the remainder of said
circuit during said two-shot molding technique.
15. A housing as set forth in claim 10, wherein an antenna is
connected to said circuit board as a separate board, and said
separate board being positioned to be non-parallel to a plane of
said circuit.
Description
BACKGROUND OF THE INVENTION
[0001] This invention relates to improvements in the manufacture of
remote entry transmitters.
[0002] Modern vehicles are often provided with remote entry systems
for unlocking the vehicle doors, locking the vehicle doors,
unlocking the trunk, etc. from a distance. These devices are
desirably made as small as possible. On the other hand, and
contrary to the goal of making the transmitters small, it has
become desirable to include more and more electrical features into
the devices. In addition, the range of the devices is somewhat
dependent on the size of the antenna associated with the
transmitter. The antennas have typically been relatively long, and
have been formed as part of a planar circuit board. Typically, the
antennas wrap around the outer periphery of the circuit board, and
are parallel to the other circuit traces.
[0003] Traditionally these remote entry devices are manufactured by
forming two separate plastic housing elements, and sandwiching a
circuit board between the two. Switches and other portions are then
added to the device. This has required a large number of parts, and
several assembly steps.
[0004] So-called two-shot molding techniques are known wherein
devices are formed by utilizing different plastic materials.
Two-shot molding has been proposed for forming electrical
components, wherein a plateable and a non-plateable plastic are
each molded at different stages in a plastic mold. The plateable
material is then provided with a conductive molding to form
electrical components. However, these methods have never been
applied to remote entry systems.
SUMMARY OF THE INVENTION
[0005] In a disclosed embodiment of this invention, a two-shot
molding technique is utilized to form one of the main housing
components of a remote entry transmitter. The housing component can
be integrally plated with circuit traces. This eliminates the need
for a separate circuit board, and thus simplifies assembly.
[0006] Two-shot molding has typically not been utilized to provide
an outer housing element which must have an aesthetically desirable
appearance. Typically, the two-shot molding techniques have been
for hidden elements. The present invention now utilizes the
two-shot molding for an outer surface, which is distinct from the
prior art. Moreover, the two-shot molding techniques have never
been utilized for remote entry systems. Both of these are
improvements over the prior art, and result in the reduction in the
number of elements associated with the remote entry systems.
[0007] In another feature of this invention, the antenna is formed
to extend generally perpendicularly to the main circuit board. This
feature is separately distinct and patentable from the two-shot
molding, although in one embodiment it is also incorporated into a
two-shot molded system.
[0008] The antenna is most preferably molded along an inner wall of
the housing member. Thus, the size and space that had previously
been required for the antenna to extend parallel to the circuit
board is no longer necessary. Instead, the antenna is now placed on
a surface area, the sidewall, which had not previously been
utilized for any electrical components. In this way, the size of
the remote transmitter can be made smaller.
[0009] In a second embodiment, the antenna is formed on a separate
board which is attached to the main circuit board, and which also
extends perpendicularly to the main circuit board. More generally,
this aspect of the invention is placing the antenna at a
non-parallel angle to the plane of the circuit board.
[0010] These and other features of the present invention can be
best understood from the following specification and drawings, the
following of which is a brief description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1A shows a remote entry transmitter.
[0012] FIG. 1B is a cross-sectional view through FIG. 1a.
[0013] FIG. 2 is a bottom view of the remote entry transmitter.
[0014] FIG. 3 is a view along the circle 3 of FIG. 1B.
[0015] FIG. 4 shows another feature of one embodiment of the
present invention.
[0016] FIG. 5 shows a second embodiment of the present
invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0017] A remote entry transmitter, or key fob, as they are
typically known, is shown in FIG. 1A. An outer housing 22 has a
textured surface, or other surface which provides a pleasing visual
appearance. A signalling portion 26 includes a plurality of
switches that allow an operator to request various functions from
the transmitter 20.
[0018] FIG. 1B is a cross-sectional view through the transmitter
20. As shown, an outer housing 22 is connected to a bottom cover
24. A switch cover 26 is connected to the housing 22. A surface 28
may be provided to form a portion of the housing 22. Circuit traces
36 are integrally formed with the housing 22. A battery 32 is in
contact with the circuit traces 36.
[0019] As shown in FIG. 2, the circuit traces 36 incorporate an
antenna 34 extending around the outer periphery of the outside wall
of the housing. Further, circuit traces 36 are formed on the main
circuit 30. Battery clips 38 which may hold the battery, and also
form the contacts, are integrally formed with the housing 22, and
hold the battery 32.
[0020] As shown in FIG. 3A, the housing 22 is formed by a plateable
plastic 40 and a non-plateable plastic 39. The antenna 34 is formed
on a plateable portion, as are the circuit traces 36.
[0021] As shown in FIG. 3B, a mold 80 has areas A and B. Area A may
be utilized to form the plateable portion of the housing 22. Area B
then injects a second plastic which is non-plateable. From area B
the housing 22 can be taken to a place wherein the conductive
material to form the traces 36 and 34 are then placed onto the
plateable material. The conductive material does not stick to the
non-plateable material. This two-shot molding technique is known in
the prior art. However, it has not been utilized for forming remote
entry transmitters. Moreover, it has not been utilized to form the
decorative outer surfaces such as are found at several areas in the
housing 22.
[0022] As shown in FIG. 4, the housing 22 may include electrical
elements 44 and 46 which snap into the circuit traces 36. The
function of the elements 44 and 46 may be as known. One element
would be an RF transmitter for sending a signal to a vehicle based
receiver. It is the manufacture of the circuit traces by the
two-shot molding technique which is inventive. Further, the
positioning of the antenna 34 on the side wall 47 is also
inventive. Again, the antenna 34 may be formed by the two-shot
molding technique. The positioning of the antenna to extend
generally perpendicular to the main surface of the traces 36 and
the circuit 30 provides packaging benefits. In the past, the
antenna 34 has been generally planar and parallel to the circuit
board. By positioning the antenna non-parallel to the circuit
board, less size is required. Moreover, the sidewall 47 has been
necessary to provide clearance for elements such as elements 44 and
46. However, its surface area has not been used for positioning
electrical components. Thus, by forming the antenna on that
sidewall better packaging is achieved.
[0023] FIG. 5 shows another embodiment 50 wherein a first circuit
board 51 has the main circuit traces 52. A second circuit board 53
is plugged into circuit board 51 and includes the antenna 54. By
positioning the circuit board 54 at a non-parallel angle (here
perpendicular) the packaging benefits described above can be
achieved.
[0024] Preferred embodiments of this invention have been disclosed;
however, a worker of ordinary skill in the art would recognize that
modifications would come within the scope of this invention. For
that reason, the following claims should be studied to determine
the true scope and content of this invention.
* * * * *