Casting process for embedding a flat flexible electrical or electronic component in a plastic cover, uses tool plates which support only certain areas of the component during molding

摘要

The flexible component (1) is clamped between tool plates (9,10) of a molding tool (8) whose cavity conforms to the final shape of the plastic cover. The tool plates only contact specific areas of the flat sides of the component leaving exposed areas which are subsequently covered by plastic material. Independent claims are also included for: (a) a molding tool for the process which has pairs of component-clamping tool plates (9,10) with structured surfaces comprising raised areas for contacting components (1) and recesses areas (V) allowing liquid polymer to flow around components during molding; (b) a flexible component comprising a conductive film embedded in a plastic grid or net structure; (c) a vehicle steering column switch with the plastic coated end of the conductive film inside the switch and carrying contacts or switches while the other end of the conductive film forms a connector to the vehicle power circuits.