U.S. patent application number 13/958912 was filed with the patent office on 2014-02-13 for device module and method of manufacturing the same.
This patent application is currently assigned to HOSIDEN CORPORATION. The applicant listed for this patent is HOSIDEN CORPORATION. Invention is credited to Takeshi ISODA, Koji SHINODA.
Application Number | 20140043771 13/958912 |
Document ID | / |
Family ID | 49118458 |
Filed Date | 2014-02-13 |
United States Patent
Application |
20140043771 |
Kind Code |
A1 |
ISODA; Takeshi ; et
al. |
February 13, 2014 |
DEVICE MODULE AND METHOD OF MANUFACTURING THE SAME
Abstract
The invention provides a device module that can be manufactured
with a die. The device module includes a plastic part, a device, a
holder, and an external connection. The device is embedded in the
plastic part. The holder is embedded in the plastic part and
includes an exposed portion exposed from the plastic part in a
thickness direction of the plastic part in such a manner as to
close a housing recess of the die. The external connection is
connected to the device and partially fixed to the holder. The
external connection includes a lead-out portion insertable in the
housing recess of the die. The lead-out portion is embedded in the
plastic part and being led out of the plastic part in the thickness
direction. Alternatively, the lead-out portion is led through and
out of the holder in the thickness direction.
Inventors: |
ISODA; Takeshi; (Yao-shi,
JP) ; SHINODA; Koji; (Yao-shi, JP) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
HOSIDEN CORPORATION |
Yao-shi |
|
JP |
|
|
Assignee: |
HOSIDEN CORPORATION
Yao-shi
JP
|
Family ID: |
49118458 |
Appl. No.: |
13/958912 |
Filed: |
August 5, 2013 |
Current U.S.
Class: |
361/728 ;
29/825 |
Current CPC
Class: |
H05K 7/02 20130101; B29C
45/14065 20130101; H05K 13/04 20130101; H05K 5/0247 20130101; B29L
2031/3481 20130101; G06F 1/169 20130101; G06F 3/038 20130101; B29K
2667/003 20130101; B29C 2045/14131 20130101; Y10T 29/49117
20150115; G06F 3/041 20130101; G06F 1/1656 20130101; B29C 33/126
20130101 |
Class at
Publication: |
361/728 ;
29/825 |
International
Class: |
H05K 7/02 20060101
H05K007/02; H05K 13/04 20060101 H05K013/04 |
Foreign Application Data
Date |
Code |
Application Number |
Aug 7, 2012 |
JP |
2012-174790 |
Claims
1. A device module manufacturable with a die, the device module
comprising: a plastic part; a device being a sensor, an electronic
component, or a circuit board, the device being embedded in the
plastic part; a holder embedded in the plastic part, the holder
including an exposed portion exposed from the plastic part in a
thickness direction of the plastic part in such a manner as to
close a housing recess of the die; and an external connection
connected to the device and partially fixed to the holder, the
external connection including: a lead-out portion insertable in the
housing recess of the die, the lead-out portion being embedded in
the plastic part and being led out of the plastic part in the
thickness direction, or alternatively the lead-out portion being
led through and out of the holder in the thickness direction.
2. The device module according to claim 1, wherein the holder
includes: a base embedded in the plastic part, and the exposed
portion protruding from the plastic part in the thickness direction
in such a manner as to fit in the housing recess of the die.
3. The device module according to claim 2, wherein the exposed
portion of the holder is tapered.
4. The device module according to claim 1, wherein the die includes
a fitting projection provided on an edge of the housing recess, and
the exposed portion includes a fitting recess to fit over the
fitting projection.
5. The device module according to claim 1, the device module
further comprising: a sheet having a first face provided with the
plastic part, wherein the external connection includes an embedded
portion embedded in the plastic part, and at least a part of the
embedded portion is disposed on the first face of the sheet, and
the holder is disposed on the at least the part of the embedded
portion.
6. The device module according to claim 5, wherein a gap is left
between the holder and the sheet, and the gap is filled with
plastic material of the plastic part.
7. The device module according to claim 1, wherein the holder has a
through hole passing through the holder in the thickness direction
to receive therethrough the lead-out portion of the external
connection.
8. The device module according to claim 1, wherein the external
connection is partially fixed to an outer face of the holder, and
the external connection and the holder in combination close the
housing recess of the die.
9. The device module according to claim 1, wherein the lead-out
portion of the external connection is partially embedded in the
holder.
10. The device module according to claim 1, wherein the holder
comprises a plurality of pieces surrounding a part of the lead-out
portion of the external connection.
11. The device module according to claim 1, wherein the holder is
made of plastic material that is the same as or in a same group as
that of the plastic part.
12. A method of manufacturing a device module, the method
comprising: partially fixing an external connection to a holder, a
first end of the external connection being connected to a device,
the device being a sensor, an electronic component, or a circuit
board; placing the device, a first end portion of the external
connection, and the holder into a cavity of first and second dies,
inserting a second end portion of the external connection into a
housing recess of the first die, and closing the housing recess of
the first die with the holder; and in this state, injecting plastic
material into the cavity to insert-mold the device, the first end
portion of the external connection, and the holder in the plastic
material.
13. The method according to claim 12, wherein the closing of the
housing recess includes fitting a distal portion of the holder in
the housing recess of the first die.
14. The method according to claim 13, wherein the distal portion of
the holder is tapered.
15. The method according to claim 13, wherein at least a part of an
edge of the housing recess of the first die forms a tapered
portion.
16. The method according to claim 12, wherein the closing of the
housing recess includes fitting a fitting projection into a fitting
recess of the holder, the fitting projection being provided on an
edge of the housing recess of the first die.
17. The method according to claim 12, wherein the placing of the
device, the first end portion of the external connection, and the
holder into the cavity includes placing a sheet in the cavity,
disposing at least a part of the external connection on the sheet,
disposing the holder on the at least the part of the external
connection, and bringing the holder into contact with the first die
to close the housing recess of the first die, and the injecting of
the plastic material includes injecting the plastic material on the
sheet to insert-mold the device, the first end portion of the
external connection, and the holder on the sheet with the plastic
material.
18. The method according to claim 12, wherein the placing of the
device, the first end portion of the external connection, and the
holder includes bringing the holder into contact with the first die
and the second die to close the housing recess of the first
die.
19. The method according to claim 12, wherein the closing of the
housing recess of the first die including fixing the holder to the
first die.
20. The method according to claim 17, wherein a gap is left between
the holder and the sheet in the cavity, and the injecting of the
plastic material into the cavity includes flowing the plastic
material into the gap.
21. The method according to claim 12, wherein the holder has a
through hole passing through the holder in the thickness direction,
and the fixing of the external connection to the holder includes
inserting the external connection into the through hole of the
holder.
22. The method according to claim 12, wherein the fixing of the
external connection to the holder includes fixing a part of the
external connection to an outer face of the holder, and the closing
of the housing recess of the first die includes closing the housing
recess with the part of the external connection and the holder.
23. The method according to claim 12, wherein the fixing of the
external connection to the holder includes insert-molding a part of
the external connection in the holder.
24. The method according to claim 12, wherein the holder includes a
plurality of pieces configured to surround a part of the external
connection, the fixing of the external connection to the holder
includes combining the plurality of pieces to surround the part of
the external connection.
25. The method according to claim 12, wherein the holder is made of
plastic material that is the same as or in a same group as that of
the plastic part.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application claims priority under 35 U.S.C.
.sctn.119 of Japanese Patent Application No. 2012-174790 filed on
Aug. 7, 2012, the disclosure of which is expressly incorporated by
reference herein in its entity.
BACKGROUND OF THE INVENTION
[0002] 1. Technical Field
[0003] The invention relates to device modules and methods of
manufacturing the device modules.
[0004] 2. Background Art
[0005] A conventional device module includes a film, a plastic part
provided on the film, a functional device embedded in the plastic
part, and a transmission cable. The transmission cable has a first
end portion connected to the functional device and embedded in the
plastic part together with the functional device, and a remaining
portion protruding from the plastic part in the thickness direction
of the plastic part (see FIG. 3 of Japanese Unexamined Patent
Publication No. 2011-126236).
SUMMARY OF INVENTION
[0006] When the plastic part is molded on the film using a die, the
above remaining portion of the transmission cable is housed in a
housing recess of the die. The housing recess communicates with a
cavity in the die. To prevent the ingress of plastic material into
the housing recess, it is required that the shape of the housing
recess should conform to the outer shape of the remaining portion
of the transmission cable. However, meeting this requirement would
make it very difficult to insert the remaining portion of the
transmission cable into the housing recess of the die.
[0007] The invention is made in view of the above circumstances.
The invention provides a device module capable of preventing
plastic material from flowing into the housing recess of the die
that houses a part of the external connection and capable of
inserting the part of the external connection easily into the
housing recess of the die. The invention also provides a method of
manufacturing the device module.
[0008] The device module according to an aspect of the invention
can be manufactured with a die. The device module includes a
plastic part, a device, a holder, and an external connection. The
device is a sensor, an electronic component, or a circuit board,
the device being embedded in the plastic part. The holder is
embedded in the plastic part and includes an exposed portion
exposed from the plastic part in a thickness direction of the
plastic part in such a manner as to close a housing recess of the
die. The external connection is connected to the device and
partially fixed to the holder. The external connection includes a
lead-out portion insertable in the housing recess of the die. The
lead-out portion is embedded in the plastic part and being led out
of the plastic part in the thickness direction. Alternatively, the
lead-out portion is led through and out of the holder in the
thickness direction.
[0009] In the device module in accordance with this aspect, the
holder is embedded in the plastic part, and the exposed portion of
the holder is exposed from the plastic part in the thickness
direction in such a manner as to close a housing recess of the die.
The external connection is partially fixed to the holder, and the
lead-out portion of the external connection is led out of the
plastic part or the holder in the thickness direction. This
arrangement makes it possible to insert the lead-out portion of the
external connection into the housing recess of the die and close
the housing recess of the die with the exposed portion of the
holder when embedding the device and the holder in the plastic part
with the die (when molding plastic material). Therefore, it is
possible to prevent the ingress of the plastic material of the
plastic part into the housing recess of the die. Further, the
housing recess of the die can be sized such as to receive the
lead-out portion of the external connection with ease because the
housing recess will be closed with the exposed portion of the
holder.
[0010] The holder may include a base embedded in the plastic part
and the exposed portion protruding from the plastic part in the
thickness direction in such a manner as to fit in the housing
recess of the die. In the device module in accordance with this
aspect, the holder can easily close the housing recess of the die
because the exposed portion of the holder, which protrudes from the
plastic part, fits in the housing recess of the die when molding
the plastic material.
[0011] The exposed portion of the holder may be tapered. The device
module in accordance with this aspect is adapted for easy fitting
of the exposed portion of the holder into the housing recess of the
die when molding the plastic material.
[0012] If the die includes a fitting projection provided on an edge
of the housing recess, the exposed portion may include a fitting
recess to fit over the fitting projection. In the device module in
accordance with this aspect, the holder can easily close the
housing recess of the die because the fitting projection of the die
fits in the fitting recess of the exposed portion when molding the
plastic material.
[0013] The device module may further include a sheet having a first
face provided with the plastic part. The external connection may
include an embedded portion embedded in the plastic part. At least
a part of the embedded portion may be disposed on the first face of
the sheet, and the holder is disposed on the at least the part of
the embedded portion. In the device module in accordance with this
aspect, the sheet, at least a part of the embedded portion, and the
holder are stacked in this order. For this reason, when molding the
plastic material, the holder is disposed on the part of the
embedded portion on the first face of the sheet, closes the housing
recess of the die, and is in contact with the die. In other words,
the holder is securely held between the part of the embedded
portion on the first face of the sheet and the die, reducing the
possibility of movement of the holder and the external connection
due to pressure on the holder by the plastic material injected into
the die.
[0014] A gap may be left between the holder and the sheet. The gap
may be filled with plastic material of the plastic part. In the
device module in accordance with this aspect, the gap between the
holder and the sheet is filled with plastic material of the plastic
part, so that the outer shape of the holder is unlikely to appear
on the sheet. This improves the surface accuracy of the portion of
the sheet opposed to the holder.
[0015] The holder may have a through hole passing through the
holder in the thickness direction to receive therethrough the
lead-out portion of the external connection. The device module in
accordance with this aspect is so configured as to fix the lead-out
portion to the holder with ease, merely by inserting the lead-out
portion of the external connection into the through hole of the
holder.
[0016] The external connection may be partially fixed to an outer
face of the holder. The external connection and the holder in
combination may close the housing recess of the die. The device
module in accordance with this aspect is so configured as to fix
the lead-out portion to the holder with ease, merely by fixing the
lead-out portion of the external connection to the outer face of
the holder.
[0017] The lead-out portion of the external connection may be
partially embedded in the holder. In the device module in
accordance with this aspect, the lead-out portion of the external
connection can be partially embedded in the holder by
insert-molding or other means. Therefore, it is easy to fix the
lead-out portion to the holder.
[0018] The holder may include a plurality of pieces surrounding a
part of the lead-out portion of the external connection. The device
module in accordance with this aspect is so configured as to fix
the lead-out portion to the holder with ease, merely by combining
the pieces of the holder so as to surround the lead-out portion of
the external connection.
[0019] The holder may be made of plastic material that is the same
as or in a same group as that of the plastic part. In the device
module in accordance with this aspect, the holder is visually
unobtrusive when seen through the plastic part, thereby enhancing
the aesthetic appearance of the device module.
[0020] A method of manufacturing method a device module according
to the invention includes partially fixing an external connection
to a holder, a first end of the external connection being connected
to a device, the device being a sensor, an electronic component, or
a circuit board; placing the device, a first end portion of the
external connection, and the holder into a cavity of first and
second dies, inserting a second end portion of the external
connection into a housing recess of the first die, and closing the
housing recess of the first die with the holder; and in this state,
injecting plastic material into the cavity to insert-mold the
device, the first end portion of the external connection, and the
holder in the plastic material.
[0021] In the manufacturing method in accordance with this aspect,
when the device and the holder are insert-molded in the plastic
material using the first and second dies, it is possible to close
the housing recess of the first die, by inserting the second end
portion of the external connection into the housing recess of the
first die. It is therefore possible to prevent the ingress of the
plastic material into the housing recess of the first die. Further,
the housing recess of the die can be sized such as to receive the
lead-out portion of the external connection with ease because the
housing recess will be closed with the holder.
[0022] The closing of the housing recess may include fitting a
distal portion of the holder in the housing recess of the first
die. The manufacturing method in accordance with this aspect makes
it easy to close the housing recess of the die with the holder, by
fitting the distal portion of the holder in the housing recess.
[0023] The distal portion of the holder may be tapered. The
manufacturing method in accordance with this aspect makes it easy
to fit the distal portion of the holder in the housing recess of
the die when molding the plastic material.
[0024] At least a part of an edge of the housing recess of the
first die may form a tapered portion. The manufacturing method in
accordance with this aspect makes it possible to easily fit the
distal portion of the holder into the housing recess because the
tapered portion guides the distal portion of the holder into the
housing recess of the first die.
[0025] The closing of the housing recess may include fitting a
fitting projection into a fitting recess of the holder. The fitting
projection may be provided on an edge of the housing recess of the
first die. The manufacturing method in accordance with this aspect
makes it easy to close the housing recess of the die with the
holder, by fitting the fitting projection of the first die in the
fitting recess of the holder.
[0026] The placing of the device, the first end portion of the
external connection, and the holder into the cavity may include
placing a sheet in the cavity, disposing at least a part of the
external connection on the sheet, disposing the holder on the at
least the part of the external connection, and bringing the holder
into contact with the first die to close the housing recess of the
first die. The injecting of the plastic material may include
injecting the plastic material on the sheet to insert-mold the
device, the first end portion of the external connection, and the
holder on the sheet with the plastic material.
[0027] In the manufacturing method in accordance with this aspect,
when molding the plastic material, the holder is disposed on a part
of the external connection on the first face of the sheet, closes
the housing recess of the die, and is in contact with the die. In
other words, the holder is securely held between the first and
second dies via the sheet and the part of the external connection,
reducing the possibility of movement of the holder and the external
connection due to pressure on the holder by the plastic material
injected into the cavity.
[0028] The placing of the device, the first end portion of the
external connection, and the holder may include bringing the holder
into contact with the first die and the second die to close the
housing recess of the first die. In the manufacturing method in
accordance with this aspect, the holder is securely held between
the first and second dies when molding the plastic material,
reducing the possibility of movement of the holder and the external
connection due to pressure on the holder by the plastic material
injected into the cavity.
[0029] The closing of the housing recess of the first die may
include fixing the holder to the first die. In the manufacturing
method in accordance with this aspect, the holder is fixed to the
first die when molding the plastic material, reducing the
possibility of movement of the holder and the external connection
due to pressure on the holder by the plastic material injected into
the cavity.
[0030] A gap may be left between the holder and the sheet in the
cavity. The injecting of the plastic material into the cavity may
include flowing the plastic material into the gap. In the
manufacturing method in accordance with this aspect, the gap
between the holder and the sheet is filled with the plastic
material of the plastic part, so that the outer shape of the holder
is unlikely to appear on the sheet. This improves the surface
accuracy of the portion of the sheet opposed to the holder.
[0031] The holder may have a through hole passing through the
holder in the thickness direction. The fixing of the external
connection to the holder may include inserting the external
connection into the through hole of the holder. Alternatively, the
fixing of the external connection to the holder may include fixing
a part of the external connection to an outer face of the holder.
In this case, the housing recess may be closed with the part of the
external connection and the holder. Further alternatively, the
fixing of the external connection to the holder may include
insert-molding a part of the external connection in the holder.
[0032] The holder may include a plurality of pieces configured to
surround a part of the external connection. The fixing of the
external connection to the holder may include combining the parts
to surround the plurality of pieces of the external connection.
[0033] The holder may be made of plastic material that is the same
as or in a same group as that of the plastic part. In the device
module in accordance with this aspect, the holder is visually
unobtrusive when seen through the plastic part, thereby enhancing
the aesthetic appearance of the device module.
BRIEF DESCRIPTION OF DRAWINGS
[0034] FIG. 1 is a schematic sectional view showing a device module
in accordance with the First Embodiment of the invention.
[0035] FIG. 2 is a view illustrating a process of manufacturing the
device module.
[0036] FIG. 3 is a schematic sectional view showing a device module
in accordance with the Second Embodiment of the invention.
[0037] FIG. 4 is a schematic sectional view showing a device module
in accordance with the Third Embodiment of the invention.
[0038] FIG. 5A is a schematic sectional view showing a device
module in accordance with the Fourth Embodiment of the
invention.
[0039] FIG. 5B is a schematic sectional view showing a process of
fixing a holder to an external connection in a method of
manufacturing the device module.
[0040] FIG. 6 is a schematic sectional view showing a device module
in accordance with the Fifth Embodiment of the invention.
[0041] FIG. 7 is a view for illustrating a process of manufacturing
the device module.
[0042] FIG. 8 is a schematic sectional view showing a device module
in accordance with an example modification of the First
Embodiment.
DESCRIPTION OF EMBODIMENTS
[0043] First to Fifth Embodiments of the invention will be
described below.
First Embodiment
[0044] First, a device module in accordance with the First
Embodiment of the invention will be described with reference to
FIG. 1. The device module shown in FIG. 1 is a touch sensing
device. The device module includes a sheet 100, a plastic part 200,
a touch sensor 300 (device), an external connection 400, and a
holder 500. These constituents of the device module will be
described below in detail. In FIG. 1, D1 refers to the thickness
direction of the device module and the plastic part 200, and D2
refers to the lengthwise direction of the device module. D1 is
orthogonal to D2. The short direction (not shown) of the device
module is orthogonal to D1 and D2.
[0045] The sheet 100 is a substantially rectangular flexible film
of optically transparent plastic material such as a PET
(polyethylene terephthalate) film or an acrylic film. The sheet 100
has a first face 101 (an inner face) and a second face 102 (an
outer face). Ornamental printing is provided on the entire region
or a partial region (e.g., a circumferential region, or one end in
the lengthwise direction D2 or in the short direction) of the first
face 101 of the sheet 100.
[0046] The plastic part 200 is an insulating member of
thermosoftening or thermosetting plastic material (e.g.
polycarbonate (PC), polymethylmethacrylate (PMMA), epoxy resin, or
the like). The plastic part 200 is generally of U-shape in
sectional view, and it is provided on the first face 101 of the
sheet 100. The plastic part 200 has first and second faces 201, 202
in the thickness direction D1. As the plastic part 200 is formed on
the first face 101 of the sheet 100, the sheet 100 generally
adheres to or is integrated with the plastic part 200 and has
hardened (has lost flexibility) generally in a U-shaped curve
extending along the second face 202 of the plastic part 200. The
second face 102 of the sheet 100 has a flat central portion serving
as a touch sensing surface of the device module.
[0047] The touch sensor 300 is a capacitive touch panel of
generally rectangular shape and in rigid or flexible sheet form.
The touch sensor 300 can detect a detection object such as a finger
that touches the touch sensing surface of the sheet 100. The touch
sensor 300 is fixed to a central portion of the first face 101 of
the sheet 100 and embedded in the plastic part 200. The touch
sensor 300 extends substantially parallel to the touch sensing
surface of the sheet 100.
[0048] If the touch sensor 400 is in a rigid transparent sheet
form, it may have any one of the configurations (1) to (3)
indicated below. If the touch sensor 400 is in a flexible
transparent sheet form (if it is a film sensor), it may have any
one of the configurations (4) to (6) indicated below. [0049] 1) The
touch sensor 300 includes a first transparent substrate having
first and second faces in its thickness direction D1, a plurality
of first transparent electrodes provided on the first face of the
first transparent substrate, and a plurality of second transparent
electrodes provided on the second face of the first transparent
substrate. [0050] 2) The touch sensor 300 includes a first
transparent substrate, a plurality of first transparent electrodes
provided on the first transparent substrate, an insulating layer
provided on the first transparent substrate so as to cover the
first transparent electrodes, and a plurality of second transparent
electrodes provided on the insulating layer. [0051] 3) The touch
sensor 300 includes a first transparent substrate having a first
face, a second transparent substrate having a first face opposed to
the first face of the first transparent substrate, a plurality of
first transparent electrodes provided on the first face of the
first transparent substrate, and a plurality of second transparent
electrodes provided on the first face of the second transparent
substrate. [0052] 4) The touch sensor 300 includes a flexible
insulating first transparent film having first and second faces in
its thickness direction D1, a plurality of first transparent
electrodes provided on the first face of the first transparent
film, and a plurality of second transparent electrodes provided on
the second face of the first transparent film. [0053] 5) The touch
sensor 300 includes a flexible insulating first transparent film, a
plurality of first transparent electrodes provided on the first
transparent film, a flexible insulating second transparent film
provided on the first transparent film so as to cover the first
transparent electrodes, and a plurality of second transparent
electrodes provided on the second transparent film. [0054] 6) The
touch sensor 300 includes a flexible insulating first transparent
film having a first face, a flexible insulating second transparent
film having a first face opposed to the first face of the first
transparent film, a plurality of first transparent electrodes
provided on the first face of the first transparent film, and a
plurality of second transparent electrodes provided on the first
face of the second transparent film.
[0055] The external connection 400 is flexible. Specifically, the
external connection 400 is a flexible printed circuit or a flexible
insulating transparent film. The external connection 400 has an
embedded portion 410 and a lead-out portion 420. The embedded
portion 410 is embedded in the plastic part 200 of the external
connection 400 and fixed to the central portion of the first face
101 of the sheet 100. The embedded portion 410 includes a
lengthwise first end of the external connection 400. The lead-out
portion 420 is a portion excluding the embedded portion 410 of the
external connection 400. The lead-out portion 420 includes a
lengthwise second end of the external connection 400.
[0056] If the external connection 400 is a flexible printed
circuit, the first end of the external connection 400 is connected
to at least one of the first and second transparent substrates of
the touch sensor 300, or to at least one of the first and second
transparent films of the touch sensor 300. Such flexible printed
circuit includes a plurality of conductive lines connected to first
and second transparent electrodes. If the external connection 400
is a transparent film, the first end of the external connection 400
is integrally connected to at least one of the first and second
transparent substrates of the touch sensor 300, or to at least one
of the first and second transparent films of the touch sensor 300.
Such transparent film includes a plurality of conductive lines
connected to the first and second transparent electrodes.
[0057] The holder 500 is a truncated conical block made of the same
plastic material or a plastic material of the same group as the
plastic part 200 (for example, polycarbonate (PC),
polymethylmethacrylate (PMMA), epoxy resin, or the like). The
holder 500 includes a base 510, an exposed portion 520, and a
through hole 530. The base 510 is the basal portion of the holder
500 and is embedded in the plastic part 200. The base 510 includes
a mounted portion 511 and an unmounted portion 512. The mounted
portion 511 is mounted on a part of the embedded portion 410 on the
first face 101 of the sheet 100. That is, the sheet 100, the
embedded portion 410, and the holder 500 are stacked in this order.
The unmounted portion 512 of the base 510 is disposed leaving a gap
from the first face 101 of the sheet 100. The gap is filled with
plastic material of the plastic part 200.
[0058] The exposed portion 520 is the distal portion of the holder
500 continuously connected to the base 510, and it protrudes (is
exposed) from the first face 201 of the plastic part 200 to one
side in the thickness direction D1 (upward in FIG. 1). The exposed
portion 520 is tapered.
[0059] The through hole 530 is a rectangular through hole passing
through the holder 500 in the thickness direction D1 (passing
through from the bottom face of the base 510 to the top face
(distal face) of the exposed portion 520). The dimensions of the
through hole 530 (dimensions in the lengthwise direction D2 and the
short direction) are slightly larger than the outer dimensions of
the lead-out portion 420 of the external connection 400 (dimensions
in the lengthwise direction D2 and the short direction of the
lead-out portion 420 as oriented in the thickness direction D0. The
lead-out portion 420 extends through the through hole 530 and is
led out of the through hole 530 to the one side in the thickness
direction D1.
[0060] The device module above described may be manufactured using
first and second dies 10, 20 as illustrated in FIG. 2. The first
die 10 includes a projection 11, a housing recess 12, and a sprue
13. The projection 11 projects in the thickness direction D1 toward
the second die 20. The sprue 13 passes through the first die 10 in
the thickness direction D1. The housing recess 12 of the first die
10 open from a distal end face of the projection 11. The edge of
the housing recess 12 partly forms a tapered portion 12a (the left
part of the edge in FIG. 2). The distance between the tapered
portion and the opposed portion of the edge gradually increases
toward the open side of the housing recess 12. The housing recess
12 has dimensions on the open side (dimensions in the lengthwise
direction D2 and the short direction) larger than the outer
dimensions (dimensions in the lengthwise direction D2 and the short
direction) of the distal end of the exposed portion 520 of the
holder 500 and smaller than the outer dimensions (dimensions in the
lengthwise direction D2 and the short direction) of the base 510 of
the holder 500. The portion excluding the open side of the housing
recess 12 has dimensions (dimensions in the lengthwise direction D2
and the short direction) larger than the outer dimensions of the
lead-out portion 420 (dimensions in the lengthwise direction D2 and
the short direction of the lead-out portion 420 as oriented in the
thickness direction D1). The housing recess 12 has a dimension in
the thickness direction D1 larger than the length of the portion of
the lead-out portion 420 that is led out of the holder 500. The
second die 20 has a recess 21 adapted to receive the projection 11.
The recess 21 has a dimension in the thickness direction D (i.e.
depth) larger than the dimension in the thickness direction D (i.e.
height) of the projection 11. The recess 21 and the projection 11
received in the recess 21 define a space. This space serves as a
cavity of the combined first and second dies 10, 20. The shape of
the cavity conforms to the outer shape of the device module
excluding the lead-out portion 420 and the exposed portion 520.
[0061] A method of manufacturing the device module using the first
and second dies 10, 20 will be described below with reference to
FIG. 2. A skilled person would appreciate that the embedded portion
410 corresponds to the first end portion of the external connection
as defined in the claims, and the lead-out portion 420 corresponds
to the second end portion of the external connection as defined in
the claims.
[0062] The first step is to prepare the sheet 100 and prepare the
touch sensor 300 with the external connection 400 connected
thereto. The touch sensor 300 and the embedded portion 410 of the
external connection 400 are fixed to the first face 101 of the
sheet 100 with an adhesive. Also prepared is the holder 500. The
lead-out portion 420 of the external connection 400 is inserted
through the through hole 530 of the holder 500. The lead-out
portion 420 is thus partially fixed to the holder 500 and partially
led out of the holder 500. It should be noted that the connection
between the touch sensor 300 and the external connection 400 may be
established after the insertion of the lead-out portion 420 through
the through hole 530. Also, the touch sensor 300 and the embedded
portion 410 of the external connection 400 may be fixed to the
first face 101 of the sheet 100 with an adhesive after the
insertion of the lead-out portion 420 through the through hole
530.
[0063] Then, the sheet 100, touch sensor 300, the external
connection 400, and the holder 500 are placed into the recess 21 of
the second die 20. This causes the sheet 100 to curve generally in
a U-shape in sectional view conforming to the shape of the recess
21. At this stage, the holder 500 is aligned with the plumb line of
the housing recess 12 of the first die 10.
[0064] Then, first and second dies 10, 20 are brought close to each
other, and the projection 11 of the first die 10 is inserted into
the recess 21 of the second die 20 (i.e. the first and second dies
10, 20 are closed). This creates the cavity between the projection
11 and the recess 21. The sheet 100, the touch sensor 300, the
embedded portion 410 of the external connection 400, and the base
510 of the holder 500 are placed in the cavity. At this point, the
lead-out portion 420 of the external connection 400 is inserted
into the housing recess 12 of the first die 10, and the exposed
portion 520 of the holder 500 fits in the housing recess 12 so as
to block the housing recess 12. The tapered exposed portion 520 and
the tapered portion 12a of the housing recess 12 guide the exposed
portion 520 such that the exposed portion 520 fits in the housing
recess 12. When the exposed portion 520 fits in the housing recess
12, the mounted portion 511 of the holder 500 is mounted on the
embedded portion 410 of the external connection 400. As a result,
the holder 500 is securely held between the first die 10 and the
second die 20 via the sheet 100 and the embedded portion 410,
creating a gap between the unmounted portion 512 of the holder 500
and the sheet 100.
[0065] Then, plastic material 30 is injected through the sprue 13
of the first die 10 onto the sheet 100 into the cavity. The cavity
is filled with the plastic material 30, so that the touch sensor
300, the embedded portion 410 of the external connection 400, and
the base 510 of the holder 500 are embedded in the plastic material
30 on the sheet 100. At this point, the plastic material 30 also
flows into the gap. Then, the plastic material 30 hardens. The
hardened plastic material 30 becomes the plastic part 200. At this
point, the sheet 100 gets adhered to or integrated with the plastic
part 200 and hardens.
[0066] Then, the first and second dies 10, 20 are separated from
each other to take out the exposed portion 520 of the holder 500
and the lead-out portion 420 of the external connection 400 from
the housing recess 12 of the first die 10. This is how to
insert-molded the touch sensor 300, the embedded portion 410 of the
external connection 400, and the base 510 of the holder 500 in the
plastic part 200 on the sheet 100. The exposed portion 520 of the
holder 500 protrudes from the plastic part 200 to the one side in
the thickness direction D1. The lead-out portion 420 protrudes from
the holder 500 to the one side in the thickness direction D1.
[0067] The above described device module has at least the following
technical features and advantages. First, it is possible to block
the housing recess 12 of the first die 10 during the insert molding
process, by inserting the lead-out portion 420 of the external
connection 400 into the housing recess 12 and fitting the exposed
portion 520 of the holder 500 in the housing recess 12. It is thus
possible to prevent the ingress of the plastic material 30 into the
housing recess 12 of the first die 10 during the insert molding
process. In other words, the exposed portion 520 is configured to
block (close) the housing recess 12 to prevent the ingress of the
plastic material 30 into the housing recess 12 of the first die 10.
This configuration makes it possible to size the housing recess 12
such as to readily receive the lead-out portion 420. Therefore, it
is possible to place the lead-out portion 420 readily into the
housing recess 12 during the insert molding process (when closing
the first and second dies 10, 20).
[0068] Further advantageously, the holder 500 is securely held
during the insert molding process, between the first die 10 and the
second die 20 via the sheet 100 and the embedded portion 410. This
arrangement reduces the possibility of movement of the holder 500
and the external connection 400 fixed thereto even when the holder
500 is pressed by the plastic material 30 injected into the cavity.
Further, the gap between the holder 500 and the sheet 100 is filled
with the plastic material of the plastic part 200, so that the
outer shape of the holder 500 is unlikely to appear on the sheet
100. This improves the surface accuracy of the portion of the sheet
100 opposed to the holder. Further, the holder 500 is made of the
same plastic material as the plastic part 200 or of a plastic
material of the same group as the plastic part 200, the holder 500
is integrated with the plastic part 200. Thus, the holder 500 is
visually unobtrusive when seen through the plastic part 200,
thereby enhancing the aesthetic appearance of the device
module.
Second Embodiment
[0069] Next, a device module in accordance with the Second
Embodiment of the invention will be described with reference to
FIG. 3. The device module as shown in FIG. 3 is different from that
of the First Embodiment in the configurations of a holder 500', and
in that a lead-out portion 420' of an external connection 400' is
fixed to an outer face of the holder 500'. These differences will
be described below in detail, and overlapping descriptions will be
omitted. A symbol_'_is added to the reference numerals of the
holder and the external connection in this embodiment to
distinguish them from those of the First Embodiment.
[0070] The holder 500' is a truncated conical block made of the
same plastic material or a plastic material of the same group as
the plastic part 200 (for example, polycarbonate (PC),
polymethylmethacrylate (PMMA), epoxy resin, or the like). The
holder 500' includes a base 510' and an exposed portion 520'. The
base 510' is the basal portion of the holder 500'. The base 510' is
mounted on the first face 101 of the sheet 100 and embedded in the
plastic part 200. The exposed portion 520' is the distal portion of
the holder 500' continuously connected to the base 510' and
protrudes (is exposed) from the first face 201 of the plastic part
200 to the one side in the thickness direction D1 (upward in FIG.
3). The exposed portion 520' is tapered.
[0071] The external connection 400' generally has the same
configuration as the external connection 400. The only difference
is that the external connection 400' is partially fixed to the
outer face of the holder 500'. The external connection 400' has an
embedded portion 410' and a lead-out portion 420'. The embedded
portion 410' is partially fixed to an outer face (circumferential
face) of the base 510' of the holder 500' with an adhesive or other
means. The lead-out portion 420' is partially fixed to the outer
face (circumferential face) of the exposed portion 520' of the
holder 500' and led out of the first face 201 of the plastic part
200 to the one side in the thickness direction D1 (upward in FIG.
3).
[0072] This device module may be manufactured by the following
method using the first and second dies 10, 20 described above for
the First Embodiment. A skilled person would appreciate that the
embedded portion 410' corresponds to the first end portion of the
external connection as defined in the claims, and the lead-out
portion 420' corresponds to the second end portion of the external
connection as defined in the claims.
[0073] The first step is to prepare the touch sensor 300 with the
external connection 400' connected thereto and the holder 500'. A
part of the external connection 400' (a part of the embedded
portion 410' and a part of the lead-out portion 420') is fixed to
the outer face of the holder 500' (outer faces of the base 510' and
the exposed portion 520') with an adhesive or other means. Also
prepared is the sheet 100. The touch sensor 300 is fixed to the
first face 101 of the sheet 100 with an adhesive, and the holder
500' is mounted on the first face 101 of the sheet 100. The holder
500' may alternatively be adhered to the first face 101 of the
sheet 100.
[0074] Then, the sheet 100, the touch sensor 300, the external
connection 400', and the holder 500' are placed into the recess 21
of the second die 20. This causes the sheet 100 to curve generally
in a U-shape in sectional view conforming to the shape of the
recess 21. At this stage, the holder 500' is aligned with the plumb
line of the housing recess 12 of the first die 10.
[0075] Then, the first and second dies 10, 20 are brought close to
each other, and the projection 11 of the first die 10 is inserted
into the recess 21 of the second die 20 (i.e. the first and second
dies 10, 20 are closed). This creates the cavity between the
projection 11 and the recess 21. The sheet 100, the touch sensor
300, the embedded portion 410' of the external connection 400', and
the base 510' of the holder 500' are placed in the cavity. At this
point, a portion of the lead-out portion 420' that is not fixed to
the holder 500' (unfixed portion) is inserted into the housing
recess 12 of the first die 10, and the housing recess 12 fittingly
receives the exposed portion 520' of the holder 500' and the
portion of the lead-out portion 420' that is fixed to the exposed
portion 520' (fixed portion), so that the housing recess 12 is
blocked up. The tapered exposed portion 520' and the tapered
portion 12a of the housing recess 12 guide the exposed portion 520'
and the fixed portion of the lead-out portion 420' such that the
exposed portion 520' and the fixed portion of the lead-out portion
420' fit in the housing recess 12. When the exposed portion 520'
and the fixed portion of the lead-out portion 420' fit in the
housing recess 12, the holder 500' is securely held between the
first die 10 and the second die 20 via the sheet 100.
[0076] Then, plastic material is injected through the sprue 13 of
the first die 10 onto the sheet 100 in the cavity. The cavity is
filled with the plastic material, so that the touch sensor 300, the
embedded portion 410' of the external connection 400', and the base
510' of the holder 500' are embedded in the plastic material on the
sheet 100. At this point, the plastic material also flows into the
gap. Then, the plastic material hardens. The hardened plastic
material becomes the plastic part 200. At this point, the sheet 100
gets adhered to or integrated with the plastic part 200 and
hardens.
[0077] Then, the first and second dies 10, 20 are separated from
each other to take out the exposed portion 520' of the holder 500'
and the lead-out portion 420' of the external connection 400' from
the housing recess 12 of the first die 10. This is how to
insert-molded the touch sensor 300, the embedded portion 410' of
the external connection 400', and the base 510' of the holder 500'
in the plastic part 200 on the sheet 100. The exposed portion 520'
of the holder 500' protrudes and is exposed from the plastic part
200 to the one side in the thickness direction D1. The lead-out
portion 420' of the external connection 400' is led out of the
plastic part 200 to the one side in the thickness direction D1.
[0078] The above described device module has at least the following
technical features and advantages. First, it is possible to block
the housing recess 12 of the first die 10 during the insert molding
process, by inserting the unfixed portion of the lead-out portion
420' of the external connection 400' into the housing recess 12 and
fitting the exposed portion 520' of the holder 500' and the fixed
portion of the lead-out portion 420' into the housing recess 12. It
is thus possible to prevent the ingress of the plastic material
into the housing recess 12 of the first die 10 during the insert
molding process. In other words, the exposed portion 520' and the
fixed portion of the lead-out portion 420' are configured to block
(close) the housing recess 12 to prevent the ingress of the plastic
material into the housing recess 12 of the first die 10. This makes
it possible to size the housing recess 12 such as to readily
receive the lead-out portion 420'. Therefore, it is possible to
place the lead-out portion 420' readily into the housing recess 12
during the insert molding process (when closing the first and
second dies 10, 20).
[0079] Further advantageously, the holder 500' is securely held
during the insert molding process, between the first die 10 and the
second die 20 via the sheet 100. This arrangement reduces the
possibility of movement of the holder 500' and the external
connection 400' fixed thereto even when the holder 500 is pressed
by the plastic material injected into the cavity. Further, the
holder 500' is made of the same plastic material as the plastic
part 200 or of a plastic material of the same group as the plastic
part 200, the holder 500' is integrated with the plastic part 200.
Thus, the holder 500' is visually unobtrusive when seen through the
plastic part 200, thereby enhancing the aesthetic appearance of the
device module. In addition, as the holder 500' to be integrated
with the plastic part 200 is mounted on the sheet 100, the sheet
100 is less likely to have a sink mark.
Third Embodiment
[0080] Next, a device module in accordance with the Third
Embodiment of the invention will be described with reference to
FIG. 4. The device module as shown in FIG. 4 is different from that
of the First Embodiment in that the lead-out portion 420 of the
external connection 400 is embedded in a holder 500'' by insert
molding. These differences will be described below in detail, and
overlapping descriptions will be omitted. A symbol _''.sub.-- is
added to the reference numerals of the holder in this embodiment to
distinguish them from that of the First Embodiment.
[0081] The holder 500'' generally has the same configuration as the
holder 500. The only difference is that the holder 500'' has no
through hole 530. As shown in FIG. 4, the holder 500'' includes a
base 510'' and an exposed portion 520'', and the base 510''
includes a mounted portion 511'' and an unmounted portion 512''.
The lead-out portion 420 of the external connection 400 is
partially embedded in the holder 500'' so as to pass from the
bottom face of the base 510'' of the holder 500'' to the top face
(distal face) of the exposed portion 520''.
[0082] The lead-out portion 420 of the external connection 400 may
be embedded in the holder 500'' in the following method using a die
(not shown). First, the external connection 400 is prepared. The
external connection 400 may or may not be connected to the touch
sensor 300. A part of the lead-out portion 420 of the external
connection 400 is placed in the die, into which plastic material is
injected. As a result, the lead-out portion 420 of the external
connection 400 is partially embedded (insert-molded) in the holder
500'' and passes from the bottom face of the base 510'' of the
holder 500'' to the top face of the exposed portion 520''. As in
the First Embodiment, the external connection 400 with the holder
500'' is placed in the cavity of the first and second dies 10, 20
to manufacture the device module.
[0083] This device module can achieve the same effects as those in
the First Embodiment.
Fourth Embodiment
[0084] Next, a device module in accordance with the Fourth
Embodiment of the invention will be described with reference to
FIG. 5A. The device module as shown in FIG. 5A is different from
that of the First Embodiment in that the holder 500''' consists of
pieces 501''', 502''' that surround a part of the lead-out portion
420 of the external connection 400. The difference will be
described below in detail, and overlapping descriptions will be
omitted. symbol_'''_is added to the reference numerals of the
holder in this embodiment to distinguish them from those of the
First Embodiment.
[0085] The holder 500''' includes the pieces 501''', 502'''. The
pieces 501''', 502''' are made of the same plastic material or a
plastic material of the same group as the plastic part 200 (for
example, polycarbonate (PC), polymethylmethacrylate (PMMA), epoxy
resin, or the like). The pieces 501''', 502''' are combined with
each other to have a truncated conical shape similar to that of the
holder 500. The inner face of the piece 501''' has a long groove
530''' extending in the thickness direction D1. The dimensions of
the long groove 530''' (dimensions in the lengthwise direction D2
and the short direction) are slightly larger than the dimensions of
the lead-out portion 420 of the external connection 400 (dimensions
in the lengthwise direction D2 and the short direction of the
lead-out portion 420 as oriented in the thickness direction D1).
When the pieces 501''', 502''' are combined, the long groove 530'''
is covered with the piece 502''' and ready to receive the lead-out
portion 420 therethrough. In other words, a part of the lead-out
portion 420 is surrounded by the pieces 501''', 502'''. The holder
500''' includes a base 510''' and an exposed portion 520''', and
the base 510''' includes a mounted portion 511''' and an unmounted
portion 512''', as shown in FIG. 5A and FIG. 5B. These constituents
have the same configurations as those of the holder 500.
[0086] The lead-out portion 420 of the external connection 400 may
be fixed to the holder 500''' in the steps as described below with
reference to FIG. 5B. The first step is to prepare the touch sensor
300 with the external connection 400 connected thereto. The touch
sensor 300 and the embedded portion 410 of the external connection
400 are fixed to the first face 101 of the sheet 100 with an
adhesive. Also prepared are the pieces 501''', 502'''. A part of
the lead-out portion 420 is inserted into the long groove 530''' of
the piece 501'''. Then, the piece 502''' is combined with the piece
501''' to cover the long groove 530''' of the piece 501''' with the
piece 502'''. The pieces 501''', 502''' are now combined with each
other surrounding the part of the lead-out portion 420 of the
external connection 400. As in the First Embodiment, the external
connection 400 with the holder 500''' is placed in the cavity of
the first and second dies 10, 20 to manufacture the device module.
It should be noted that the step of combining the pieces 501''',
502''' surrounding the lead-out portion 420 may be followed by the
step that the touch sensor 300 and the embedded portion 410 of the
external connection 400 are fixed to the first face 101 of the
sheet 100 with an adhesive.
[0087] Such device module can achieve the same effects as those in
the First Embodiment. Moreover, the holder 500''' is fixed to the
part of the lead-out portion 420 of the external connection 400 by
combining the pieces 501''', 502''' so as to surround the part of
the lead-out portion 420. It is thus possible to improve the
workability of fixing the holder 500''' to the external connection
400.
Fifth Embodiment
[0088] Next, a device module in accordance with the Fifth
Embodiment of the invention will be described with reference to
FIG. 6 and FIG. 7. The device module as shown in FIG. 6 generally
has the same configuration as that of the First Embodiment but
includes a holder 500'''' of a different shape from that of the
holder 500. This difference will be described below in detail, and
overlapping descriptions will be omitted. A symbol_''''.sub.-- is
added to the reference numerals of the holder in this embodiment to
distinguish them from those of the First Embodiment.
[0089] The holder 500'''' is made of the same plastic material or a
plastic material of the same group as the plastic part 200 (for
example, polycarbonate (PC), polymethylmethacrylate (PMMA), epoxy
resin, or the like). The holder 500'''' is different from the
holder 500 in that it includes an exposed portion 520'''' that does
not protrude from the first face 201 of the plastic part 200 to the
one side in the thickness direction D1 (upward in FIG. 6).
[0090] The exposed portion 520'''' has an exposed face and a
fitting recess 521''''. The exposed face of the exposed portion
520'''' faces the one side in the thickness direction D1 (upward in
FIG. 6) and is not hidden behind the first face 201 of the plastic
part 200. The central area of the exposed face around the through
hole 530'''' is dented to form the fitting recess 521''''. The
fitting recess 521'''' is of shape conforming to the outer shape of
a fitting projection 12a' of a first die 10' (to be described, see
FIG. 7). The holder 500'''' further includes a base 510'''', which
includes a mounted portion 511'''' and an unmounted portion 512''''
as shown in FIG. 6.
[0091] The device module of this embodiment may be manufactured
using the modified first die 10', in place of the first die 10, as
described below with reference to FIG. 7. The first die 10'
includes the annular fitting projection 12a' provided along the
edge of the housing recess 12. In the state where the projection 11
of the first die 10' is inserted into the recess 21 of the second
die 20, the projection 11 and the recess 21 define a space. The
space serves as a cavity of the combined first and second dies 10',
20. The shape of the cavity conforms to the outer shape of the
device module excluding the lead-out portion 420.
[0092] A method of manufacturing the device module using the first
and second dies 10', 20 will be described with reference to FIG. 7.
A skilled person would appreciate that the embedded portion 410
corresponds to the first end portion of the external connection as
defined in the claims, the lead-out portion 420 corresponds to the
second end portion of the external connection as defined in the
claims.
[0093] The first step is to prepare the sheet 100, and the touch
sensor 300 with the external connection 400 connected thereto. The
touch sensor 300 and the embedded portion 410 of the external
connection 400 are fixed to the first face 101 of the sheet 100
with an adhesive. Also prepared is the holder 500'''', and the
lead-out portion 420 of the external connection 400 is inserted
through the through hole 530'''' of the holder 500''''. The
lead-out portion 420 is thus partially fixed to the holder 500''''
and partially led out of the holder 500''''. It should be noted
that the connection between the touch sensor 300 and the external
connection 400 may be established after the insertion of the
lead-out portion 420 through the through hole 530''''. Also, the
touch sensor 300 and the embedded portion 410 of the external
connection 400 may be fixed to the first face 101 of the sheet 100
with an adhesive after the insertion of the lead-out portion 420
through the through hole 530''''.
[0094] Then, the sheet 100, the touch sensor 300, the external
connection 400, and the holder 500'''' are placed into the recess
21 of the second die 20. This causes the sheet 100 to curve
generally in a U-shape in sectional view conforming to the shape of
the recess 21. At this stage, the holder 500'''' is aligned with
the plumb line of the housing recess 12 of the first die 10'.
[0095] Then, the first and second dies 10', 20 are brought close to
each other, and the projection 11 of the first die 10' is inserted
into the recess 21 of the second die 20 (i.e. the first and second
dies 10', 20 are closed). This creates the cavity between the
projection 11 and the recess 21. The sheet 100, the touch sensor
300, the embedded portion 410 of the external connection 400, and
the holder 500'''' are placed in the cavity. At this point, the
lead-out portion 420 of the external connection 400 is inserted
into the housing recess 12 of the first die 10', and the fitting
projection 12a' of the first die 10' fits in the fitting recess
521'''' of the exposed portion 520'''' of the holder 500''''. The
exposed portion 520'''' thus covers the housing recess 12. When the
fitting projection 12a' fits in the fitting recess 521'''', the
mounted portion 511'''' of the holder 500'''' is mounted on the
embedded portion 410 of the external connection 400. As a result,
the holder 500'''' is securely held between the first die 10' and
the second die 20 via the sheet 100 and the embedded portion 410,
creating a gap between the unmounted portion 512'''' of the holder
500'''' and the sheet 100.
[0096] Then, the plastic material 30 is injected through the sprue
13 of the first die 10' onto the sheet 100 in the cavity. The
cavity is filled with the plastic material 30, so that the touch
sensor 300, the embedded portion 410 of the external connection
400, and the holder 500'''' are embedded in the plastic material 30
on the sheet 100. At this point, the plastic material 30 also flows
into the gap. Then, the plastic material 30 hardens to become the
plastic part 200. At this point, the sheet 100 adheres to or is
integrated with the plastic part 200 and hardens.
[0097] Then, when the first and second dies 10', 20 are separated
from each other to take out the lead-out portion 420 of the
external connection 400 from the housing recess 12 of the first die
10' and disengage the fitting projection 12a' of the first die 10'
from the fitting recess 521'''' of the holder 500''''. This is how
to insert-molded the touch sensor 300, the embedded portion 410 of
the external connection 400 and the holder 500'''' in the plastic
part 200 on the sheet 100. The exposed portion 520'''' of the
holder 500'''' is exposed from the plastic part 200, facing the one
side in the thickness direction D1. The lead-out portion 420 is led
out of the holder 500'''' to the one side in the thickness
direction D1.
[0098] The above described device module has at least the following
technical features and advantages. First, during the insert molding
process, the lead-out portion 420 of the external connection 400
enters the housing recess 12 of the first die 10', while the
fitting projection 12a' of the first die 10' fits in the fitting
recess 521'''' of the exposed portion 520'''' of the holder
500''''. This arrangement makes it possible to cover the housing
recess 12 of the first die 10' with the exposed portion 520''' so
as to prevent the ingress of the plastic material 30 into the
housing recess 12 of the first die 10' during the insert molding
process. In other words, the exposed portion 520'''' is configured
to cover (close) the housing recess 12 to prevent the ingress of
the plastic material 30 into the housing recess 12 of the first die
10'. This configuration makes it possible to size the housing
recess 12 such as to readily receive the lead-out portion 420.
Therefore, it is possible to place the lead-out portion 420 easily
into the housing recess 12 during the insert molding process (when
closing the first and second dies 10', 20).
[0099] Further advantageously, the holder 500'''' is securely held
during the insert molding process, between the first die 10' and
the second die 20 via the sheet 100 and the embedded portion 410.
This arrangement reduces the possibility of movement of holder
500'''' and the external connection 400 fixed thereto even when the
holder 500'''' is pressed by the plastic material 30 injected into
the cavity. Further, the gap between the holder 500'''' and the
sheet 100 is filled with the plastic material of the plastic part
200, so that the outer shape of the holder 500'''' is unlikely to
appear on the sheet 100. This improves the surface accuracy of the
portion of the sheet 100 opposed to the holder 500''''. Further,
the holder 500'''' is made of the same plastic material as the
plastic part 200 or of a plastic material of the same group as the
plastic part 200, the holder 500'''' is integrated with the plastic
part 200. Thus, the holder 500'''' is visually unobtrusive when
seen through the plastic part 200, thereby enhancing the aesthetic
appearance of the device module.
[0100] The device module of the invention is not limited to the
embodiments as described above and may be modified in any manner
within the scope of claims. Specific modifications will be
described below in detail. FIG. 8 is a schematic sectional view
showing a device module in accordance with an example modification
of the First Embodiment.
[0101] The holder of the First to Third and Fifth Embodiments is a
plastic block. The holder of the Forth Embodiment has a plurality
of plastic pieces. However, the holder may be modified in any
manner as long as it is partially fixed to the external connection
and embedded in the plastic part and as long as a part (the exposed
portion) of the holder is exposed from the plastic part in the
thickness direction of the plastic part in such a manner as to
close of the housing recess of the die. The holder may be made of
any other plastic material (e.g. elastomer), metal, or ceramic.
Alternatively, the holder may be a film coating or an adhesive
fixed to the part of the external connection.
[0102] The exposed portion of the holder of the First to Fourth
Embodiments is tapered and protrudes from the plastic part. The
exposed portion of the Fifth Embodiment is exposed from the plastic
part and has the exposed face with the fitting recess. However, the
exposed portion may be of any shape as long as a part of the
exposed portion is exposed from the plastic part in the thickness
direction of the plastic part in such a manner as to close the
housing recess of the die. For example, the exposed portion of the
holder may be modified to have a flat exposed face exposed from the
first face of the plastic part in the thickness direction. In this
case, the exposed face of the exposed portion of the holder may be
flush with the first face of the plastic part. That is, the exposed
portion of the holder may not protrude from the first face of the
plastic part. This modified exposed portion is exposed from the
plastic part in such a manner as to not fit in the housing recess
of the first die but close the housing recess. The exposed portion
may be modified to have a cylindrical, conical, or semi-spherical
shape that can fit in the housing recess of the die. The exposed
portion need not be entirely tapered and may be partially tapered.
Further, the fitting recess of the exposed portion may be modified
in any manner as to fit over the fitting projection of the first
die and close the housing recess of the first die. The fitting
recess may be provided in the exposed portion protruding from the
plastic part. The base of the holder may be of any shape adapted to
be embedded in the plastic part.
[0103] The invention is not limited to the configuration in
accordance with the First, Third and Fifth Embodiments that a gap
is created between the unmounted portion of the holder and the
sheet. FIG. 8 illustrates an example modification wherein a holder
500''''' includes a base 510''''' and an exposed portion 520'''''.
The base 510''''' includes a first mounted portion 511''''' and a
second mounted portion 512'''''. The first mounted portion 511'''''
is mounted on the embedded portion 410 as in the mounted portion
511. The second mounted portion 512''''' extends further than the
first mounted portion 511''''' to the other side in the thickness
direction D1 (downward) to be mounted on the first face 101 of the
sheet 100. The second mounted portion 512''''' may be fixed to the
first face 101 of the sheet 100. The holder 500''' of the Fourth
Embodiment may also include the second mounted portion 512''''' in
place of the unmounted portion 512'''. The holder 500'''' of the
Fifth Embodiment may also include the second mounted portion
512''''' in place of the unmounted portion 512''''.
[0104] The holder may include two pieces as in the Fourth
Embodiment or may have three pieces or more. Further, the long
groove may be provided in one of the pieces as in the Fourth
Embodiment or may be provided in a plurality of pieces. In the
latter case, the long groove extending in the combined pieces
serves as a hole to receive the lead-out portion of the external
connection. The long groove may be omitted. In this case, the
pieces as combined may have a hole therebetween to receive the
lead-out portion of the external connection. The holder of the
modifications described above and the holder 500'''' of the Fifth
Embodiment may be modified to have a plurality of pieces as
described above.
[0105] The external connection may include an embedded portion and
a lead-out portion as in the First to Fifth Embodiments and the
modifications described above. However, the external connection may
be modified in any manner as long as it satisfies the following
requirements. The first requirement is that the external connection
is connected to a device to be described. The second requirement is
that the external connection is partially fixed to the holder. The
third requirement is that the external connection includes a
lead-out portion insertable in a housing recess of a die. The
fourth requirement is that the lead-out portion is embedded in the
plastic part and led out of the plastic part in the thickness
direction of the plastic part, or alternatively the lead-out
portion is led through and out of the holder in the thickness
direction. If the lead-out portion of the external connection is
led through and out of the holder in the thickness direction, the
embedded portion may be omitted.
[0106] The lead-out portion of the external connection may pass
from the bottom face to the top face (distal face) of the holder as
in the First and Third to Fifth Embodiments. However, the lead-out
portion only needs to be embedded in the plastic part and led out
of the plastic part in the thickness direction of the plastic part,
or alternatively be led through and out of the holder in the
thickness direction. For example, the lead-out portion may be
modified to pass from a side face to the distal face of the
external connection. The lead-out portion may be embedded in the
holder by insert molding or other means.
[0107] The embedded portion of the external connection may be fixed
to the first face of the sheet as in the First and Third to Fifth
Embodiments. The embedded portion may not be fixed to the sheet.
Alternatively, a part of the embedded portion may be fixed to the
sheet. In this case, the mounted portion or the first mounted
portion of the holder may be mounted on the fixed part of the
embedded portion.
[0108] The external connection may be a flexible printed circuit or
a flexible insulating transparent film as in the First to Fifth
Embodiments and the above example modification. However, the
external connection may be in any other form, such as a lead wire,
a header pin, and a rigid board.
[0109] The plastic part may be generally of U-shape in sectional
view as in the First to Fifth Embodiments and the above example
modification. However, the plastic part may be of any other shape,
such as a flat plate-like shape. The sheet may be modified to be of
any shape conforming to the shape of the plastic part.
[0110] The sheet may be provided on the plastic part as in the
First to Fifth Embodiments and the above example modification, but
the sheet may be omitted. Further, the sheet may be transparent and
flexible as in the First to Fifth Embodiments and the above example
modification. However, the sheet may alternatively be translucent
and flexible, opaque and flexible, translucent and inflexible, or
opaque and inflexible. The sheet may be made of a material that
does not harden (does not lose flexibility) after the molding of
the plastic part. The sheet may be provided with ornamental
printing as in the embodiments or without any ornamental
printing.
[0111] The device of the device module may be a touch sensor used
as a capacitive touch panel. However, the device of the invention
may be any type of sensor, any type of electronic component, or any
type of circuit board. The sensor may be of any type including a
touch panel of type other than the capacitive type (for example, a
touch panel of resistive film-type, optical-type, ultrasonic-type,
or in-cell type), a touch switch (for example, a touch switch of
capacitive, resistive film-type, optical-type, ultrasonic-type, or
in-cell type), or a sensor other than the touch panel and the touch
switch (for example, a magnetic sensor, an optical sensor, or a
light-dark sensor) can be used. In the touch panel and the touch
switch (touch sensor), the electrode may be provided on the sheet
by any well-known printing method. The touch panel and the touch
switch may be opaque. The touch sensing surface of the touch panel
or the touch switch is not limited to the second surface of the
sheet. For example, the touch sensing surface may be an outer
surface of a panel provided on the side of the outer surface of the
sheet. Also, an electronic component or a circuit board in place of
a sensor may be embedded in the plastic part. Examples of the
electronic component include active components (for example,
semiconductor) and passive components (for example, a resistor, a
capacitor, and a coil). The sensor, electronic component, or
circuit board may be embedded in the plastic part in any manner.
For example, the sensor, electronic component, or circuit board may
be embedded in the plastic part leaving a gap from the sheet.
[0112] The device module may be manufactured using the first and
second dies as described for the First to Fifth Embodiments.
However, the first and second dies may be modified in any manner as
long as they are configured to be combined with each other to
create a cavity therebetween and the first die has a housing recess
communicating with the cavity. For example, the first and second
dies may each have a recess and the recesses of the combined first
and second dies may form a cavity. Alternatively, the first and
second dies may be modified such that a projection provided on the
second die is inserted into a recess provided in a first die, and
the projection and the recess may form a cavity. In this case, the
housing recess may communicate with the recess of the first die.
The sprue can be provided in at least one of the first and second
dies.
[0113] In the First to Fourth Embodiments, a part of the edge of
the housing recess 12 (on the left in the associated figure) forms
the tapered portion 12a. However, the tapered portion 12a may be
omitted. The entire edge of the housing recess may be tapered such
that distances between opposed areas of the edge in the lengthwise
direction and in the short direction of the device module gradually
increase toward the open side of housing recess. The minimum
requirement to guide the exposed portion of the holder into the
housing recess is that the exposed portion is tapered, and/or that
at least a part of the edge of the housing recess of the first die
forms a tapered portion in such a manner that the distance between
the opposed areas of the edges gradually increases toward the open
side.
[0114] The edge of the housing recess 12 may be provided with the
annular fitting projection 12a' as in the Fifth Embodiment.
However, the fitting projection 12a' may be omitted. Alternatively,
the fitting projection may be of any other shape conforming to the
shape of the fitting recess of the holder.
[0115] The device module of the First to Fifth Embodiments may be
manufactured as described above or by any other methods including
partially fixing an external connection to a holder, a first end of
the external connection being connected to a device, the device
being a sensor, an electronic component, or a circuit board;
placing the device, a first end portion of the external connection,
and the holder into a cavity of first and second dies, inserting a
second end portion of the external connection into a housing recess
of the first die, and closing the housing recess of the first die
with the holder; and in this state, injecting plastic material into
the cavity to insert-mold the device, the first end portion of the
external connection, and the holder in the plastic material.
[0116] As in the First and Third to Fifth Embodiments, the holder
may be securely held between the first die and the second die via
the sheet and the embedded portion of the external connection when
the sheet, the embedded portion of the external connection (the
first end portion of the external connection), and the holder are
placed in the cavity. As in the Second Embodiment, the holder may
be securely held between the first die and the second die via the
sheet when the sheet, the embedded portion of the external
connection (the first end portion of the external connection), and
the base of the holder are placed in the cavity. However, the
holder may be held in any other manner as long as the holder is
brought into contact with the first die to close the housing recess
of the first die and into direct or indirect contact with the
second die when the device, the first end portion of the external
connection, and the holder are placed in the cavity of the first
and second dies. If the sheet is omitted as mentioned above, the
holder may be held directly between the first and second dies
during the insert molding process. Alternatively, the holder may be
securely held between the first and second dies via something else
other than the sheet and/or the embedded portion of the external
connection during the insert molding process. Further
alternatively, the holder may be fixed to the first die with an
adhesive so as to close the housing recess of the first die during
the insert molding process. This arrangement can reduce the
possibility of the movement of the holder and the external
connection due to the injection pressure of the plastic material
during the insert molding process without securely holding the
holder between the first and second dies. Naturally, the holder may
be fixed to the first die with an adhesive so as to close the
housing recess of the first die during the insert molding process
even when the holder is securely held between the first and second
dies.
[0117] As in the First and Third to Fifth Embodiments, the touch
sensor and the embedded portion of the external connection may be
fixed to the first face of the sheet during the insert molding
process. As in the Second Embodiment, the touch sensor may be fixed
to the first face of the sheet during the insert molding process.
However, these components do not have to be fixed to the first face
of the sheet during the insert molding process. For example, the
components may be fixed on the projection of the first die. In this
case, the components may be embedded in the plastic part with a gap
from the sheet. Alternatively, the components may be fixed to a
spacer mounted on the first face of the sheet. It is also possible
to fix only these components to the sheet, the projection, or the
spacer without fixing the embedded portion of the external
connection to any of the sheet, the projection, or the spacer. It
is also possible to fix only the embedded portion of the external
connection to the sheet, the projection, or the spacer without
fixing the components to any of the sheet, the projection, or the
spacer.
[0118] It should be appreciated that the above-described
embodiments and modifications are described by way of examples
only. The materials, shapes, dimensions, numbers, arrangements, and
other configurations of the device module and the first and second
dies may be modified as long as they provide the same
functions.
TABLE-US-00001 REFERENCE SIGNS LIST 100 sheet 101 first face 102
second face 200 plastic part 201 first face 202 second face 300
touch sensor (device) 400 external connection 410 embedded portion
(first end portion of external connection) 420 lead-out portion
(second end portion of external connection) 500 holder 510 base 520
exposed portion (distal portion of holder) 530 through hole 400'
external connection 410' embedded portion (first end portion of
external connection) 420' lead-out portion (second end portion of
external connection) 500' holder 510' base 520' exposed portion
(distal portion of holder) 500'' holder 510'' base 520'' exposed
portion (distal portion of holder) 500''' holder 501''' part 510'''
base 520''' exposed portion (distal portion of holder) 530'''
through hole 500'''' holder 501'''' part 510'''' base 520''''
exposed portion (distal portion of holder) 530'''' through hole
* * * * *