US20020154050A1 - Integrally molded remote entry transmitter - Google Patents

Integrally molded remote entry transmitter Download PDF

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Publication number
US20020154050A1
US20020154050A1 US10/176,213 US17621302A US2002154050A1 US 20020154050 A1 US20020154050 A1 US 20020154050A1 US 17621302 A US17621302 A US 17621302A US 2002154050 A1 US2002154050 A1 US 2002154050A1
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US
United States
Prior art keywords
housing
antenna
transmitter
remote entry
circuit
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Abandoned
Application number
US10/176,213
Inventor
Eric Krupp
John Nantz
John McConnell
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Lear Automotive Dearborn Inc
Original Assignee
Lear Automotive Dearborn Inc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Lear Automotive Dearborn Inc filed Critical Lear Automotive Dearborn Inc
Priority to US10/176,213 priority Critical patent/US20020154050A1/en
Publication of US20020154050A1 publication Critical patent/US20020154050A1/en
Abandoned legal-status Critical Current

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Classifications

    • HELECTRICITY
    • H04ELECTRIC COMMUNICATION TECHNIQUE
    • H04BTRANSMISSION
    • H04B1/00Details of transmission systems, not covered by a single one of groups H04B3/00 - H04B13/00; Details of transmission systems not characterised by the medium used for transmission
    • H04B1/38Transceivers, i.e. devices in which transmitter and receiver form a structural unit and in which at least one part is used for functions of transmitting and receiving
    • H04B1/3827Portable transceivers
    • H04B1/3877Arrangements for enabling portable transceivers to be used in a fixed position, e.g. cradles or boosters
    • GPHYSICS
    • G07CHECKING-DEVICES
    • G07CTIME OR ATTENDANCE REGISTERS; REGISTERING OR INDICATING THE WORKING OF MACHINES; GENERATING RANDOM NUMBERS; VOTING OR LOTTERY APPARATUS; ARRANGEMENTS, SYSTEMS OR APPARATUS FOR CHECKING NOT PROVIDED FOR ELSEWHERE
    • G07C9/00Individual registration on entry or exit
    • G07C9/00174Electronically operated locks; Circuits therefor; Nonmechanical keys therefor, e.g. passive or active electrical keys or other data carriers without mechanical keys
    • G07C9/00944Details of construction or manufacture
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01QANTENNAS, i.e. RADIO AERIALS
    • H01Q1/00Details of, or arrangements associated with, antennas
    • H01Q1/12Supports; Mounting means
    • H01Q1/22Supports; Mounting means by structural association with other equipment or articles
    • H01Q1/24Supports; Mounting means by structural association with other equipment or articles with receiving set
    • H01Q1/241Supports; Mounting means by structural association with other equipment or articles with receiving set used in mobile communications, e.g. GSM
    • H01Q1/242Supports; Mounting means by structural association with other equipment or articles with receiving set used in mobile communications, e.g. GSM specially adapted for hand-held use
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01QANTENNAS, i.e. RADIO AERIALS
    • H01Q1/00Details of, or arrangements associated with, antennas
    • H01Q1/27Adaptation for use in or on movable bodies
    • H01Q1/32Adaptation for use in or on road or rail vehicles
    • H01Q1/3208Adaptation for use in or on road or rail vehicles characterised by the application wherein the antenna is used
    • H01Q1/3233Adaptation for use in or on road or rail vehicles characterised by the application wherein the antenna is used particular used as part of a sensor or in a security system, e.g. for automotive radar, navigation systems
    • H01Q1/3241Adaptation for use in or on road or rail vehicles characterised by the application wherein the antenna is used particular used as part of a sensor or in a security system, e.g. for automotive radar, navigation systems particular used in keyless entry systems
    • HELECTRICITY
    • H04ELECTRIC COMMUNICATION TECHNIQUE
    • H04BTRANSMISSION
    • H04B1/00Details of transmission systems, not covered by a single one of groups H04B3/00 - H04B13/00; Details of transmission systems not characterised by the medium used for transmission
    • H04B1/02Transmitters
    • H04B1/03Constructional details, e.g. casings, housings
    • H04B1/034Portable transmitters
    • HELECTRICITY
    • H05ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05KPRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K1/00Printed circuits
    • H05K1/02Details
    • H05K1/0284Details of three-dimensional rigid printed circuit boards
    • HELECTRICITY
    • H05ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05KPRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K3/00Apparatus or processes for manufacturing printed circuits
    • H05K3/10Apparatus or processes for manufacturing printed circuits in which conductive material is applied to the insulating support in such a manner as to form the desired conductive pattern
    • H05K3/18Apparatus or processes for manufacturing printed circuits in which conductive material is applied to the insulating support in such a manner as to form the desired conductive pattern using precipitation techniques to apply the conductive material
    • H05K3/181Apparatus or processes for manufacturing printed circuits in which conductive material is applied to the insulating support in such a manner as to form the desired conductive pattern using precipitation techniques to apply the conductive material by electroless plating
    • H05K3/182Apparatus or processes for manufacturing printed circuits in which conductive material is applied to the insulating support in such a manner as to form the desired conductive pattern using precipitation techniques to apply the conductive material by electroless plating characterised by the patterning method

Definitions

  • This invention relates to improvements in the manufacture of remote entry transmitters.
  • 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.
  • 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.
  • 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.
  • these methods have never been applied to remote entry systems.
  • 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.
  • Two-shot molding has typically not been utilized to provide an outer housing element which must have an aesthetically desirable appearance.
  • 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.
  • 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.
  • 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.
  • the antenna is most preferably molded along an inner wall of the housing member.
  • 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.
  • 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.
  • FIG. 1A shows a remote entry transmitter
  • FIG. 1B is a cross-sectional view through FIG. 1 a.
  • FIG. 2 is a bottom view of the remote entry transmitter.
  • FIG. 3 is a view along the circle 3 of FIG. 1B.
  • FIG. 4 shows another feature of one embodiment of the present invention.
  • FIG. 5 shows a second embodiment of the present invention.
  • FIG. 1A 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 .
  • FIG. 1B is a cross-sectional view through the transmitter 20 .
  • 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 .
  • 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 .
  • 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 .
  • 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 .
  • 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.
  • the manufacture of the circuit traces by the two-shot molding technique which is inventive.
  • the positioning of the antenna 34 on the side wall 47 is also inventive.
  • 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.
  • 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.
  • 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.
  • 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 .
  • the circuit board 54 By positioning the circuit board 54 at a non-parallel angle (here perpendicular) the packaging benefits described above can be achieved.

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.

Description

    BACKGROUND OF THE INVENTION
  • This invention relates to improvements in the manufacture of remote entry transmitters. [0001]
  • 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. [0002]
  • 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. [0003]
  • 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. [0004]
  • SUMMARY OF THE INVENTION
  • 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. [0005]
  • 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. [0006]
  • 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. [0007]
  • 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. [0008]
  • 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. [0009]
  • 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.[0010]
  • BRIEF DESCRIPTION OF THE DRAWINGS
  • FIG. 1A shows a remote entry transmitter. [0011]
  • FIG. 1B is a cross-sectional view through FIG. 1[0012] a.
  • FIG. 2 is a bottom view of the remote entry transmitter. [0013]
  • FIG. 3 is a view along the [0014] circle 3 of FIG. 1B.
  • FIG. 4 shows another feature of one embodiment of the present invention. [0015]
  • FIG. 5 shows a second embodiment of the present invention.[0016]
  • DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
  • A remote entry transmitter, or key fob, as they are typically known, is shown in FIG. 1A. An [0017] 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.
  • FIG. 1B is a cross-sectional view through the [0018] 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.
  • As shown in FIG. 2, the [0019] 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.
  • As shown in FIG. 3A, the [0020] 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.
  • As shown in FIG. 3B, a mold [0021] 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.
  • As shown in FIG. 4, the [0022] 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.
  • FIG. 5 shows another [0023] 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.
  • 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. [0024]

Claims (15)

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.
US10/176,213 1999-01-22 2002-06-20 Integrally molded remote entry transmitter Abandoned US20020154050A1 (en)

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US09/235,701 US6433728B1 (en) 1999-01-22 1999-01-22 Integrally molded remote entry transmitter
US10/176,213 US20020154050A1 (en) 1999-01-22 2002-06-20 Integrally molded remote entry transmitter

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US10/176,213 Abandoned US20020154050A1 (en) 1999-01-22 2002-06-20 Integrally molded remote entry transmitter

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EP (1) EP1145374B1 (en)
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EP1145374B1 (en) 2004-08-04
WO2000044066A3 (en) 2000-11-23

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