IN-MOLD APPLICATIONS FOR PRESENT DAY APPLICATIONS

There has been a great deal of anticipation and expectation about In-Mold Electronics (IME). The intense interest lies in the benefits that can be obtained with IME parts. They could essentially replace a complex array of electromechanical switches and dials with an effective three-dimensional part having all of the existing capabilities and far more built into the part itself. The IME part can incorporate force sensing and capacitive controls with audible or haptic feedback. Clear displays, using a much smaller footprint than dedicated controls, that change based on user input can significantly reduce the space needed for numerous switches and controls by grouping controls on various control screens such as a climate control screen or comfort controls for seating and lighting.

With the Integration of the switching and function controls into a circuit that is formed into a three-dimensional shape then over molded to provide an aesthetically pleasing yet highly functional control panel, the process provides a very desirable alternative for designers. With reductions in weight, complexity, volume and the ease of assembly and shortened manufacturing time and costs are also part of the mix, this technology becomes highly desirable!

Adoption of this technology is straightforward and has been simplified. Prototypes can be made using designs and print layouts provided by DuPont. There is a completed form for thermo-forming parts and molds that are available for molding parts. Prints can be made, using specific films, and processed using conventional equipment used for printing today’s membrane switches. Arrangements can be made for forming and molding to be completed at a specific facility in the southwest. The process conditions are available and will be shared with customers for each step needed for the successful fabrication of prototypes. There is a proven system in place from start to finish.

The resulting parts will have many practical design elements incorporated into the functioning component. These include buttons with capacitive functions that have various draw depths and forms as well as printed traces and crossovers with variable widths and spacing, attached leds, and pin connectors for attaching chipsets and controllers.

Parts can be formed at Hytech and molded at IMS, (In-Mold Solutions), in Arizona. Operations and testing can be performed with an Atmel MCU interface which will allow complete operation of the controls for testing and demonstration. Test data is available. There is a proven system in place to make working parts from start to finish. This is a clear example of many companies combining efforts to foster “Success Through Collaboration”.