Electronic device

Abstract

A device comprising a laminate (2) comprising at least two layers (3.sub.1, 3.sub.2, 3.sub.3, 3.sub.4, 3.sub.5) and a plurality of electronic components (5, 6, 7, 8) disposed between two layers. At least one of the layers (3.sub.1, 3.sub.4) supports conductive tracks (10, 11) arranged to connect electronic components.

Claims

1. A device comprising: a laminate which comprises at least four layers including first and second outer layers and first and second intermediate layers interposed between the first and second outer layers; and a plurality of electronic components disposed between the first and second outer layers; wherein at least one of the at least four layers support conductive tracks arranged to connect to corresponding electronic components of the plurality of electronic components and the second intermediate layer supports at least one conductive track, wherein the first and second intermediate layers overlap and an overlapping portion of the first intermediate layer lies in a plane, and wherein a non-overlapping portion of the second intermediate layer lies above or lies in plane with the plane of the overlapping portion of the first intermediate layer, and an overlapping portion of the second intermediate layer lies below the overlapping portion of the first intermediate layer, and wherein the at least four layers are laminated together by an adhesive between each layer of the laminate.

2. The device according to claim 1, wherein the conductive tracks comprise conductive ink printed on at least one of the at least four layers.

3. The device according to claim 2, wherein the conductive ink comprises a metal-based conductive ink, optionally a silver-based conductive ink, or a carbon-based ink.

4. The device according to any claim 1, wherein the at least four layers include sheets of card.

5. The device according to claim 1, wherein at least one intermediate layer is configured to provide at least one cavity.

6. The device according to claim 5, wherein each of the first intermediate layer or the second intermediate layer include at least one aperture.

7. The device according to claim 1, wherein the laminate has a thickness of at least 2 mm.

8. The device according to claim 1, wherein the laminate has a thickness no more than 50 mm.

9. The device according to claim 1, wherein an outer face of the laminate has an area of at least 50 cm.sup.2.

10. The device according to claim 1, wherein an outer face of the laminate has an area of at least 500 cm.sup.2.

11. The device according to claim 1, wherein the laminate includes at least five layers.

12. The device according to claim 1, wherein the at least four layers were formed from portions of a sheet.

13. The device according to claim 12, wherein the sheet was folded to form the laminate.

14. The device according to claim 12, wherein the sheet includes at least one slit or slot extending between an edge of the sheet and a line along the sheet, wherein the slit or slot allows a first portion of the sheet on one side of the slit or slot to be folded along a first section of the line in a first direction of folding, and a second portion of the sheet on the other side of the slit or slot to be left unfolded or to be folded along a second section of the line in a second, opposite direction of folding.

15. The device according to claim 12, wherein the laminate was trimmed so as to remove folded edges.

16. The device according to claim 1, wherein the plurality of electronic components include a battery.

17. The device according to claim 1, wherein the plurality of electronic components include a speaker.

18. The device according to claim 1, wherein the plurality of electronic components include an integrated circuit.

19. The device according to claim 1, wherein the device further comprises at least one switch.

20. The device according to claim 19, wherein the at least one switch is formed using at least three layers of the laminate and comprises a first region of conductive material disposed on a surface of a first layer which is one of the at least three layers of the laminate and a second region of conductive material disposed on a facing surface of a second layer which is one of the at least three layers of the laminate, wherein a third layer which is one of the at least three layers of the laminate spaces apart the first and second layers.

21. The device according to claim 19, wherein the at least one switch comprises a capacitive sensing switch.

22. The device according to claim 1, wherein the device further comprises at least one light emitter.

23. The device according to claim 1, which is a printed article.

24. The device according to claim 1, which is a book.

25. The device according to claim 1, which is a game.

26. The device according to claim 1, which is a greeting card.

27. The device of claim 1, wherein a bottom surface of one of the plurality of electronic components is mounted on the first outer layer, wherein the one of the plurality of electronic components is in a cavity of the laminate and wherein the at least one conductive track supported by the second intermediate layer makes contact with a conductive contact on a top surface of the one of the plurality of electronic components and also makes contact with a first conductive track on the first outer layer.

28. The device of claim 27, wherein the at least four layers further include a third intermediate layer, wherein a part of the non-overlapping portion of the second intermediate layer that lies above the overlapping portion of the first intermediate layer, when the part is in plane with the third intermediate layer.

29. The device of claim 27, wherein the bottom surface of the one of the plurality of electronic components has a conductive contact thereon that makes contact with a second conductive track that is on the first outer layer.

30. The device of claim 29, wherein the one of the plurality of electronic components is a battery.

31. The device of claim 27, wherein the non-overlapping portion of the second intermediate layer is bent in part so as to route the at least one conductive track supported by the second intermediate layer between the conductive contact on the top surface of the one of the plurality of electronic components and the first conductive track on the first outer layer.

32. The device of claim 31, wherein the one of the plurality of electronic components is a battery.

33. The device of claim 27, wherein the one of the plurality of electronic components is a speaker.

34. The device of claim 1, wherein one or more of the at least one of the plurality of electronic components is a microcontroller housed in a cavity inside the laminate.

35. The device of claim 1, wherein the at least four layers comprise fiber-based material, plastic, or both fiber-based material and plastic.

36. The device of claim 35, wherein a bottom surface of one of the plurality of electronic components is mounted on the first outer layer, wherein the one of the plurality of electronic components is in a cavity of the laminate and wherein the at least one conductive track supported by the second intermediate layer makes contact with a conductive contact on a top surface of the one of the plurality of electronic components and also makes contact with a first conductive track on the first outer layer.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) Certain embodiments of the present invention will now be described, by way of example, with reference to the accompanying drawings, in which:

(2) FIG. 1 is perspective view of a device in accordance with the present invention;

(3) FIG. 2 is a cross section of the device shown in FIG. 1 taken along the line A-A;

(4) FIG. 3 illustrates a printing stage;

(5) FIG. 4 illustrates a cutting stage;

(6) FIG. 5 illustrates a laminating stage;

(7) FIGS. 6a to 6d illustrates the device shown in FIG. 1 taken along the line A-A at different stages during manufacture;

(8) FIG. 7 is a plan view of a sheet which can be folded to form a laminate;

(9) FIG. 8 is a perspective view of a first way in a sheet can be folded;

(10) FIG. 9 is a perspective view of a second way in which a sheet can be folded;

(11) FIG. 10a illustrates a first type of user input device;

(12) FIG. 10b illustrates a second type of user input device; and

(13) FIG. 10c illustrates a third type of user input device.

DETAILED DESCRIPTION OF CERTAIN EMBODIMENTS

(14) Referring to FIGS. 1 and 2, a device 1 (herein also referred to as an interactive article) in accordance with the present invention is shown.

(15) The interactive article 1 comprises a laminate 2 comprising five layers 3.sub.1, 3.sub.2, 3.sub.3, 3.sub.4, 3.sub.5 of card including first and second outer layers 3.sub.1, 3.sub.5 (hereinafter referred to a bottom layer and top layer respectively) and three intermediate layers 3.sub.2, 3.sub.3, 3.sub.4 interposed between the bottom and top layers 3.sub.1, 3.sub.5. The layers 3.sub.1, 3.sub.2, 3.sub.3, 3.sub.4, 3.sub.5 have the same thickness and, in this example, each have a density of about 200 gm.sup.2. However, the layers 3.sub.1, 3.sub.2, 3.sub.3, 3.sub.4, 3.sub.5 need not all have the same thickness and can have different densities, for example, having a higher density up to 350 gm.sup.2 or more. The layers 3.sub.1, 3.sub.2, 3.sub.3, 3.sub.4, are held together with an adhesive (not shown).

(16) The intermediate layers 3.sub.2, 3.sub.3, 3.sub.4 are patterned to provide cavities 4.sub.1, 4.sub.2, 4.sub.3, for example, by cutting or stamping out parts of the layers 3.sub.2, 3.sub.3, 3.sub.4. The top and/or bottom layers 3.sub.1, 3.sub.5 may also be patterned to provide holes, slots or windows to allow passage of light or sound, or to house an electronic component, such as a light emitting diode.

(17) Electronic components 5, 6, 7, 8 are housed in the cavities 4.sub.1, 4.sub.2, 4.sub.3. In this the electronic components 5, 6, 7, 8 include a battery 5, a printed circuit board 6, carrying a microcontroller 7 and other components (not shown), and a piezoelectric speaker 8. The interactive article 1 may include other electronic components 9 which are not housed in a cavity, but which are disposed in, on and/or between layers. In this case, a switch 9 in the form of a capacitive sensing pad is provided on the bottom layer 3.sub.1 but which is not housed in a cavity.

(18) The interactive article 1 may be a book, game, greeting card, poster, calendar, product packaging (such as a carton), point of sale display or other form of printed article.

(19) Referring in particular to FIG. 2, the bottom layer 3.sub.1 supports conductive tracks 10 which connect the battery 5, printed circuit board 6 and piezoelectric speaker 8. In this example, the tracks 10 are formed by printing conductive ink on the upper face of the first layer 3.sub.1. However, in some embodiments, the tracks 10 may comprise foil formed by hot- or cold-foil stamping. The electronic components 5, 6, 8 are connected to the tracks 10 using conductive glue or conductive anisotropic film (not shown). The fourth layer 3.sub.4 also supports conductive tracks 11 which connect the battery 5, printed circuit board 6 and piezoelectric speaker 8. The tracks 11 are formed by printing conductive ink on the underside of the fourth layer 3.sub.4.

(20) Referring to FIGS. 3, 4 and 5, a method of manufacturing the interactive article 1 will now be described.

(21) Referring to FIG. 3, conductive ink 12 is printed on a face 13 of a sheet 14 using a printer 15. Screen printing, ink jet printing, flexography or offset printing or gravure can be used.

(22) As will be explained in more detail later, the layers 3.sub.1, 3.sub.2, 3.sub.3, 3.sub.4, 3.sub.5 (FIG. 2) may form part of the same sheet 14 which is creased and folded while the layers 3.sub.1, 3.sub.2, 3.sub.3, 3.sub.4, 3.sub.5 (FIG. 2) are still connected. Alternatively, the layers 3.sub.1, 3.sub.2, 3.sub.3, 3.sub.4, 3.sub.5 (FIG. 2) may be provided as separate sheets 14 and conductive ink 12 is printed on only some of the sheets 14, i.e. sheets corresponding to layers, such as the first layer 3.sub.1 (FIG. 2), requiring conductive ink.

(23) A sheet-based process may be used. For example, the printer 15 may print a series of sheets 14, each sheet 14 corresponding to the layers 3.sub.1, 3.sub.2, 3.sub.3, 3.sub.4, 3.sub.5 (FIG. 2).

(24) Alternatively, a roll-to-roll process may be used. Thus, the sheets 14 may form part of a web 16. For example, the layers 3.sub.1, 3.sub.2, 3.sub.3, 3.sub.4, 3.sub.5 (FIG. 2) may form a section of the web 16 or be adjacently arranged in a given area. This allows the web 16 to be cut, e.g. in into sections, each section providing a sheet 14 corresponding to the layers 3.sub.1, 3.sub.2, 3.sub.3, 3.sub.4, 3.sub.5 (FIG. 2). Instead, separate webs can be used for different layers. Thus, a given web can be cut to provide layers of one given type.

(25) As explained earlier, conductive ink need not be used. For example, a metal foil may be stamped onto the surface of the sheet 14 using, for example, a hot foil process. The foil may comprise aluminium, copper, silver, gold or other suitable metal.

(26) Referring to FIG. 4, slits 17.sub.1 can be cut in the sheet 14 and apertures or slots 17.sub.2 cut out from the sheet 14 using a cutting machine 18, such as planar cutter form or a rotary die cutter. A sheet-based process may be used. Alternatively, a roll-to-roll process may be used. The cutting process may define the sheets 14.

(27) Referring to FIG. 5, electronic components 19 are mounted on the sheets 14, adhesive (not shown) is applied to the sheet 14 and the sheet 14 is folded to form the device 1 using one or more converting machine(s) 20. The electronic components 19 may be mounted from a web or using a pick-and-place robot (not shown).

(28) FIGS. 6a to 6d illustrate the article 1 at different stages during manufacture. Although the layers 3.sub.1, 3.sub.2, 3.sub.3, 3.sub.4, 3.sub.5 are shown separately in FIGS. 6a to 6d, the layers 3.sub.1, 3.sub.2, 3.sub.3, 3.sub.4, 3.sub.5 may in fact form part of the same sheet, as shown by lines in chain.

(29) FIG. 6a show the layers 3.sub.1, 3.sub.2, 3.sub.3, 3.sub.4, 3.sub.5 after a printing stage. A first layer 3.sub.1 supports conductive tracks 10 on an upper face 21 and the second layer 3.sub.2 support conductive tracks 11 on a lower face 22. However, as will be explained in more detail later, the first and second layers 3.sub.1, 3.sub.2 may simply be different parts of the same sheet 14 with the sheet 14 folded.

(30) As shown in FIG. 6b, during a cutting stage, regions 23.sub.1, 23.sub.2, 23.sub.3, 23.sub.4, 23.sub.5, 23.sub.6 of the second, third and fourth layers 3.sub.2, 3.sub.3, 3.sub.4 are cut out (e.g. stamped out).

(31) As shown in FIG. 6c, after the cutting stage, apertures 24.sub.1, 24.sub.2, 24.sub.3, 24.sub.4, 24.sub.5, 24.sub.6 are formed in the second, third and fourth layers 3.sub.2, 3.sub.3, 3.sub.4. An aperture 24.sub.4 in the third layer 3.sub.3 is aligned with an aperture 24.sub.6 in the fourth layer 3.sub.4.

(32) FIG. 6d shows the article 1 during a laminating stage.

(33) As shown in FIG. 6d, first and second regions 25.sub.1, 25.sub.2 of the second layer 3.sub.2 overlap the battery 5 and piezoelectric speaker 8. An aperture 24.sub.2 is defined between the first and second regions 25.sub.1, 25.sub.2 of the second layer 3.sub.2 which forms a cavity 4.sub.2 for the printed circuit board 7. A region or strip 26.sub.1 of the third layer 3.sub.3 runs over the aperture 24.sub.2 and overlaps inner portions 27.sub.1, 27.sub.2 of the first and second regions 25.sub.1, 25.sub.2 of the second layer 3.sub.2. Thus, the strip 26.sub.1 (pressed down by an overlying strip 26.sub.2 of the fourth layer 3.sub.4) pushes down the inner portions 27.sub.1, 27.sub.2 of the second layer 3.sub.2.

(34) Outer portions 28.sub.1, 28.sub.2 of the first and second regions 25.sub.1, 25.sub.2 of the second layer 3.sub.2 are not pushed down and are free to stay or rise to a different level by being pushed up by the battery 5 and piezoelectric speaker 8 into apertures 24.sub.4, 24.sub.5 in the third layer 3.sub.3.

(35) The first and second regions 25.sub.1, 25.sub.2 have conductive ink on their undersides 22 and so conductive tracks 11 can be routed from the top of the components 5, 8 to conductive tracks 10 on the layer 3.sub.1 below.

(36) Expressed differently, the second layer 3.sub.2 bends upwards in areas where it comes into contact with the upper surfaces of the battery 5 and piezoelectric speaker 8. The components 5, 8 have different heights and so the layer 3.sub.2 is routed to different heights in a self-organised way as it comes into contact with the battery 5 and piezoelectric speaker 8. The third layer 3.sub.3 forms cavities 4.sub.1, 4.sub.3 (FIG. 1) for the battery 5 and piezoelectric speaker 8. The fourth layer 3.sub.4 only forms a cavity 4.sub.1 (FIG. 1) for the battery 5 and also compresses the upper contact formed by second layer 3.sub.2 on top of the piezoelectric speaker 8. The top layer 3.sub.5 compresses the top contact formed by second layer 3.sub.2 on top of the battery 5. In this way, conductive tracks 11 can be routed to any layer using the components 5, 8 themselves to cause the layers to rise up to different levels with their upper surfaces.

(37) The article 1 may be processed further, for example, by trimming edges of the laminate 2 and/or by covering the article 1 in a protective plastic layer.

(38) This process can be carried out using printing and converting processes. Thus, the article 1 can be manufactured in a simple way.

(39) A laminate can be created from several sheets laminated together each with a different pattern cut out and with different printed tracks and, if required, graphics. Several similar constructions can be created on one sheet.

(40) As mentioned earlier, the layers 3.sub.1, 3.sub.2, 3.sub.3, 3.sub.4, 3.sub.5 (FIG. 2) can be cut out from one sheet of card. This can reduce the amount of different tooling required for each layer.

(41) Referring to FIG. 7, a sheet 30 is shown which includes a set of slits 31.sub.1, 31.sub.2 and fold lines 32.sub.1, 32.sub.2, 32.sub.3. The sheet 30 is rectangular having first and second long edges 33, 34 and short ends 35, 36. The slits 31.sub.1, 31.sub.2 into the sheet 30 perpendicularly to the edges 33, 34 and define six areas 37.sub.1, 37.sub.2, 37.sub.3, 37.sub.4, 37.sub.5, 37.sub.6.

(42) Referring to FIG. 8, a six-layer stack can be formed by folding the areas on top of each other using folds a, b, c, d, e, f.

(43) Referring to FIG. 9, a six-layer stack can be formed without using any slits by folding a sheet 30 along line g, then along line h and then line i.

(44) Thus, the interactive article 1 shown in FIG. 1 can be fabricated from a single sheet using this approach which helps to simplify manufacture.

(45) As explained earlier, the interactive article 1 (FIG. 1) can include switches. Such switches can be formed in the laminate using or not using cavities.

(46) Referring to FIGS. 10a to 10c, first, second and third electrical switches are shown.

(47) FIG. 10a shows a first push button switch 41.sub.1. The switch 41.sub.1 can be formed using three layers 42.sub.1, 42.sub.2, 42.sub.3. The layers include a first bottom layer 42.sub.1, a second intermediate layer 42.sub.2 and a third, top layer 42.sub.3. Two pads of conductive material 43.sub.1, 43.sub.2 comprising, for example, conductive ink are formed on an upper surface 44 of the bottom layer 42.sub.1. The second layer 42.sub.3 has an aperture 45 which is aligned with the conductive pads 43.sub.1, 43.sub.2 so that both pads are visible through the aperture 45. The top layer 42.sub.3 has a pad of conductive material 46, which again can be conductive ink, disposed on an underside 47 of the layer 42.sub.3. Laminating the layers 42.sub.1, 42.sub.2, 42.sub.3 forms a cavity 48.

(48) As shown in FIG. 10a, the user can press their finger 49 on the topside 5 of the top sheet 42.sub.3 and press the top conductive pad 46 and bridges the bottom two conductive pads 43.sub.1, 43.sub.2.

(49) FIG. 10b shows another switch 41.sub.2. The switch is similar to the first switch 411 shown in FIG. 10b except that the top sheet 43.sub.2 and top contact 46 are omitted. The two conductive pads 43.sub.1, 43.sub.2 are bridged directly by the user's finger 49.

(50) FIG. 10c shows a capacitive sensing element 41.sub.3.

(51) In this case, second and third layers 42.sub.2, 42.sub.3 cover a pad of conductive material 43, e.g. conductive ink, disposed on the upper surface 44 of the bottom sheet 42.sub.1. The pad is sensitive to capacitance change due to the user's finger 49.

(52) It will be appreciated that many modifications may be made to the embodiments hereinbefore described.

(53) The laminate can comprise fewer layers or more layers. For example, the laminate may comprise only two layers.

(54) The sheets need not be made of card, but can be formed from paper or another fibre-based material. The sheets may be formed from a plastic. Laminated sheets, for example comprising sheets of card and plastic, may be used.