Body produced by an in-mold process and process for the production thereof

Abstract

A body (1, 1, 1) produced by an in-mold process has a first film (2, 2, 2) with at least one electrical or electronic functional layer (25). In a functional area (20a, 20a, 20a) of this functional layer, at least one electrical or electronic component is provided, and at least one electrical connection for this is provided in a contact area (20b, 20b, 20b). The first film is partially back-injection molded with a plastic main material (3, 3, 3) such that the contact area (20b, 20b, 20b) is at least partially free from this plastic main material (3). Suitable formation of the first film (2, 2, 2) guarantees that a tab (F) separated from the plastic main material (3, 3, 3) is provided which adjoins a back-injection molded part of the first film in an area of surface (20c, 20c, 20c) of the body which is at a distance from an edge (31, 31) of the body delimiting the surface (30) with the first film.

Claims

1. A body which has a first film with at least one electrical or electronic functional layer, wherein at least one electrical or electronic component is provided in a functional area of the functional layer, and wherein at least one electrical connection is provided in a contact area of the at least one functional layer, which electrical connection is galvanically coupled to at least one component, wherein the body furthermore comprises a plastic main material with which the first film is partially back-injection molded such that the contact area is at least partially free from plastic main material, wherein the first film is formed such that a tab separated from the plastic main material is provided by a non-back injection-molded part of the first film, which tab adjoins a back-injection molded part of the first film in an area of surface of the body, which is at a distance from an edge of the body delimiting the surface with the first film.

2. The body according to claim 1, wherein the plastic main material predefines a shape of the body which makes it possible at least partially to bring the tab up against the surface of the plastic main material on its side with the first film.

3. The body according to claim 1, wherein the body has a flat surface, on which the first film is arranged, and wherein the tab can be brought into a position or is located in a position in which it protrudes at an angle from the range of from 15 to 90 to the plane from an area of surface which is adjoined on all sides in respect of the surface by plastic main material.

4. The body according to claim 1, wherein the body has a curved surface, on which the first film is arranged, and wherein the tab can be brought into a position or is located in a position in which it protrudes at an angle from the range of from 75 to 0 to a surface normal of the curved surface at an area of surface which is adjoined on all sides in respect of the surface by plastic main material.

5. The body according to claim 1, wherein a transition from a back-injection molded part of the first film to a non-back-injection molded part of the film takes place along a line on the surface which is at a distance of at least 8 mm, from an edge contour of the body delimiting the surface with the first film.

6. The body according to claim 1, further comprising a second film or a lacquer package which is likewise back-injection molded with the plastic main material and has a decoration layer which is over the whole surface or partial and which provides at least one item of information in respect of the at least one electrical or electronic component.

7. The body according to claim 1, wherein the functional layer comprises capacitive components which provide a touch panel functionality.

8. The body according to claim 1, further comprising a stiffening element with a thickness from the range of from 140 to 580 m, or an additional contact element with a thickness from the range of from 1 to 15 m, on the tab.

9. The body according to claim 1, wherein the plastic main material is a thermoplastic which comprises polymethyl (meth)acrylate, acrylonitrile-butadiene-styrene, polycarbonate or polyamide.

10. The body according to claim 1, wherein the plastic main material is transparent at least in areas.

11. The body according to claim 1, wherein the functional layer has a plurality of conductor traces which consist of silver, copper, aluminum, chromium or of a metal alloy, and which have a width of between 1 m and 40 m and have a distance from each other of between 10 m and 5 mm and are provided in a layer thickness of from 30 to 60 nm.

12. The body according to claim 1, wherein the functional layer has a plurality of conductor traces which consist of silver, copper, aluminum, chromium or of a metal alloy, and which have a width of 100 m or more.

13. The body according to claim 1, wherein the functional layer comprises metal nanowires made of silver, copper, gold, metal nanoparticles made of silver, copper or gold, carbon nanotubes, carbon nanoparticles, graphene, or organic conductors or polyaniline or provides organic light-emitting diodes, inorganic or organic photovoltaic cells, display elements provided using electroluminescent materials, electrochromic materials or electrophoretic materials, integrated circuits or inorganic or organic memories.

14. The body according to claim 1, further comprising a substrate carrying the functional layer and made of polyethylene terephthalate, polypropylene, polycarbonate, or polyethylene naphthalate, which is provided in a thickness of between 35 and 60 m.

15. The body according to claim 14, wherein the substrate is arranged between the functional layer and the plastic main material.

16. The body according to claim 14, wherein the functional layer is arranged between the substrate and the plastic main material.

17. The body according to claim 1, further comprising an adhesion-promoter layer at least on the part of the first film back-injection molded with plastic.

18. The body according to claim 17, wherein the adhesion-promoter layer consists of two partial layers which are formed from different material.

19. An electrical device, with a housing, in or against which the body according to claim 1 is placed, wherein an electrical or electronic component is arranged in the housing, which component is galvanically coupled, via the tab protruding from the plastic main material, to the electrical or electronic functional layer.

20. A process for producing the body according to claim 1 wherein a first film is inserted into an injection mold, wherein the first film, in a first area, has adhesion properties in respect of a predetermined injection-molding material which are qualitatively better than the corresponding adhesion properties in a second area of the first film, wherein the second area has the form of a tongue protruding from the first area, wherein in the process the predetermined injection-molding material is injected into the injection mold with the first film, with the result that the first film is partially back-injection molded and then the produced body is removed, in which, because of the different adhesion properties, injection-molding material adheres to the first film in the first area, but injection-molding material adheres poorly or does not adhere to the first film in the second area.

21. The process according to claim 20, wherein a film is inserted which comprises an adhesion-promoter layer in the first area.

22. The process according to claim 20, wherein a film is inserted which comprises, in the second area, a layer suppressing the adhesion.

23. A process for producing the body according to claim 1, wherein a first film is inserted into an injection mold, which film has a first area from which a second area protrudes in the form of a tongue, and wherein in the process the second area is clamped between two clamping parts and wherein injection-molding material is injected into the injection mold and thus the first area of the first film is back-injection molded.

24. The process according to claim 23, wherein the injection mold is formed such that injection-molding material is provided on both sides of a transition area from the first area to the second area of the first film.

25. The process according to claim 23, wherein the clamping elements comprise a mold half of the injection mold and either a separate slide, an inclined ejector guided in the mold half of the injection mold or a spring-loaded ejector mounted in the mold half of the injection mold.

26. The process according to claim 23, wherein the clamping elements comprise two clamping jaws that can be separated from each other by a collapsible core.

27. The process according to claim 23, wherein a first film is inserted into an injection mold, wherein the first film, in a first area, has adhesion properties in respect of a predetermined injection-molding material which are qualitatively better than the corresponding adhesion properties in a second area of the first film, wherein the second area has the form of a tongue protruding from the first area, wherein in the process the predetermined injection-molding material is injected into the injection mold with the first film, with the result that the first film is partially back-injection molded and then the produced body is removed, in which, because of the different adhesion properties, injection-molding material adheres to the first film in the first area, but injection-molding material adheres poorly or does not adhere to the first film in the second area.

28. The process according to claim 20, wherein a second film is introduced into the injection mold, which film is likewise back-injection molded.

29. The process according to claim 28, wherein, as the second film, a film is inserted which comprises a carrier layer and a transfer layer and is supplied in a roll-to-roll process, wherein, after the back-injection molding, the transfer layer at least partially adheres to the injection-molding material and is detached from the carrier layer, and wherein the carrier layer is taken away in the roll-to-roll process.

30. A film element for use as part of the body according to claim 1, which has a substrate, and an electrical or electronic functional layer, wherein the film element has, on one surface side, a first area and a second area which differ from each other by their different adhesiveness in respect of a predetermined injection-molding material.

31. The film element according to claim 30, wherein the first area is provided with an adhesion-promoter layer and the second area is not.

32. The film element according to claim 30, wherein an adhesion-promoter layer is applied over the whole surface in the first and in the second area, wherein in the second area on the adhesion-promoter layer a layer suppressing the adhesion is provided.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) Preferred embodiments of the invention are described in more detail below with reference to the drawing, in which:

(2) FIG. 1 shows a schematic sectional view through a plastic part as a body according to the invention according to a first embodiment of the invention,

(3) FIG. 2 shows a schematic section through an electronic device in which the body from FIG. 1 is used,

(4) FIGS. 3A/3B show, in top view and in section respectively, a first production stage for a film element used in the body according to the invention according to a first embodiment,

(5) FIGS. 4A/4B show, in top view and in section respectively, a second production stage for the film element used in the body according to the invention,

(6) FIGS. 5A/5B show, in top view and in section respectively, a third production stage for the film element used in the body according to the invention,

(7) FIGS. 6A/6B show, in top view and in section respectively, a fourth production stage for the film element used in the body according to the invention,

(8) FIGS. 7A/7B show, in top view and in section respectively, a film element used in the production of a body according to the invention according to a second embodiment in a first production stage,

(9) FIGS. 8A/8B show, in top view and in section respectively, the film element used in the production of the body according to the invention according to a second embodiment in a second production stage,

(10) FIGS. 9A/9B show, in top view and in section respectively, the film element used in the production of the body according to the invention according to a second embodiment in a third production stage,

(11) FIGS. 10A/10B show, in top view and in section respectively, the film element used in the production of the body according to the invention according to a second embodiment in a fourth production stage,

(12) FIGS. 11A/11B show, in top view and in section respectively, the film element used in the production of the body according to the invention according to a second embodiment in a fifth production stage,

(13) FIG. 12A shows, in section, a film element in the style of the film element shown in FIG. 11B with a further layer,

(14) FIG. 12B shows, in section, the film element from FIG. 12A after a back-injection molding, whereby a plastic part is produced,

(15) FIG. 12C shows the plastic part from FIG. 12B after the tab has been partially raised,

(16) FIGS. 13A-13D show the components used in a process for producing a body according to a first alternative, in different production stages,

(17) FIGS. 14A-14D show the components used in a process for producing a body according to a second alternative, in different production stages,

(18) FIGS. 15-17 show different layer structures for a film element that can be used in the body according to the invention, in schematic section,

(19) FIGS. 18 and 19 are top views of different embodiments of a film element that can be used in the body according to the invention,

(20) FIG. 20 is a view of a film element according to FIG. 19,

(21) FIGS. 21A-21H show, with reference to schematically shown components of an injection-molding die, different production stages of a process for producing a body according to the invention according to a third alternative,

(22) FIGS. 22A-22H show, with reference to schematically shown components of an injection-molding die, different production stages of a process for producing a body according to the invention according to a fourth alternative,

(23) FIGS. 23A-23H show, with reference to schematically shown components of an injection-molding die, different production stages of a process for producing a body according to the invention according to a fifth alternative,

(24) FIGS. 24A-24H show, with reference to schematically shown components of an injection-molding die, different production stages of a process for producing a body according to the invention according to a sixth alternative,

(25) FIGS. 25A/B show an alternative embodiment of a body according to the invention, in perspective view from above and below respectively and

(26) FIGS. 26A/B show a still further alternative embodiment of a body according to the invention, in perspective view from above and below respectively.

DETAILED DESCRIPTION OF THE INVENTION

(27) A body shown in FIG. 1 and labeled 1 throughout comprises a first film 2, injection-molding material 3 and a second film 4. The layer thicknesses of the individual components are not shown to scale here. The first film 2 forms a film element which comprises a substrate 21 which adheres, via an adhesion-promoter layer 22 (also called primer), to the injection-molding material 3. However, this adhesion only occurs in a first area 20a of the first film 2, whereas a second area 20b of the first film does not adhere to the surface 30 of the injection-molding material 3. The transition area 20c between the first and the second area is at a distance of several millimeters, for example 5 mm, from an edge contour 31 of the injection-molding material 3, see the distance d drawn in FIG. 1. The second area 20b of the first film 2 carries a strengthening element 23 which increases the stiffness of the end of the second area 20b. In addition, a contact reinforcement 24 is provided.

(28) In the present case, the first film is to be such a film which carries an electrical functional layer, for example in the form of capacitive elements for providing a touch panel functionality (with the result that the film 2 is a sensor film). Alternatively or in addition, it is possible for the film 2 to carry light-emitting diode elements, e.g. organic light-emitting diodes (OLEDs). The second area 20b, which in the present case has the form of a tab protruding from the first area 20a, can in particular be a contact area, comprise such a contact area or be only a part of a contact area; it is important that an electrical connection for the elements is provided in the electrical functional layer in the area of this tab, thus in the second area 20b, and the contact reinforcement 24 has the function of making it easier to contact this connection element with a counter contact.

(29) The significance of the protrusion of the tab results from the use of the body 1 in an electronic device 100, which is shown in FIG. 2: the electronic device comprises a housing part 5, which, however, does not form a closed housing, but rather requires that the body 1 be placed on in order to provide a housing that is closed overall. The body 1 sits, in particular in an area 11a or 11b, against its respective edge on the housing part 5. Because the tab now protrudes from the surface 30 of the injection-molding material 3, the film 2 can be contacted inside the thus-formed housing of the electronic device 100. The contacting takes place with an electronic circuit board 6, which optionally carries light-emitting elements or a display 7, which can backlight the body 1, via a plug-in connection 8. In particular, the end of the tab, thus of the second area 20b, provided with the strengthening element 23 and the contact reinforcement 24 is plugged into the plug-in connection 8, with the result that an electrical contact between the electronic circuit board 6 and the components or functional elements in the first film 2 is provided.

(30) The second film 4 can comprise a complete label, which is provided within the framework of an in-mold labeling. However, the second film 4 is preferably only the transfer layer of a transfer film which was detached from a carrier layer during the production process. In this case, the second film 4 can also be called a lacquer package.

(31) The second film 4 comprises a decoration layer or decoration sheet that is over the whole surface or partial and the function of which consists, in particular in addition to just decoration, in providing an item of information in respect of the first film 2 or the components contained therein, and in forming a protective layer against mechanical, physical and/or chemical actions. If the first film is a film with touch panel functionality, the individual touch panels can be displayed through the decoration layer. An operator then need only tap on the symbolically shown touch panels and, because of a capacitive interaction, the capacitive components in the first film 2 detect this tapping in cooperation with the electronic circuit board 6.

(32) Alternatively, the second film 4 can have exclusively the function of a protective layer. This is the case e.g. when a touchscreen is provided by the body 1, for instance for use in a smartphone; it is then desirable if the second film 4 is transparent. A display can then be arranged behind the touch panel sensor and show the item of information for operation. In this case the film need not be completely transparent, but rather can have a transparent area in the display area and a frame at the edge.

(33) There are now different possibilities for how a body in the style of the body 1 from FIG. 1 can be produced. A first process for producing such a body is described with reference to FIGS. 3a/b to 6a/b:

(34) The figures labeled B in each case display the section along the line A-A from the respectively associated figure labeled A.

(35) First the substrate 21 is provided (FIGS. 3A/B). Then a partial coating of this substrate 21 with an adhesion-promoter layer 22 takes place, see FIGS. 4A/B. Afterwards, an electrical functional layer 25 is applied to the substrate 21 on the side facing away from the adhesion-promoter layer 22, see FIGS. 5A/B. It is clear from FIG. 5A that the electrical functional layer 25 is not applied over the whole surface, but rather comprises a first area 25a from which a tongue-shaped second area 25b protrudes. The mapping on the substrate 21 is the design in which the tongue-shaped area 25b lies above the area of the substrate 21 which is not coated with the adhesion-promoter layer 22.

(36) The first film 2 is then cut, wherein essentially the functional element just described is cut out. Here too, the first area 25a and the second area 25b and the corresponding mapping of the area in the substrate 21 lying underneath it are thus obtained.

(37) If such a film 2 is now back-injection molded, the body 1 from FIG. 1 can be obtained.

(38) In a second embodiment of the process, the substrate 21 is again also provided first, see FIGS. 7A/B, but this is then coated over the whole surface with an adhesion-promoter layer 22, as can be seen in FIGS. 8A/B; FIG. 8A here represents the production stage in a partial outline. Here too, see FIGS. 9A/B, an electrical functional layer 25 is then applied which once again comprises a first area 25a and a tongue-shaped area 25b protruding from this. The adhesion-promoter layer here is now also located underneath the tongue-shaped area 25b. However, its action is inhibited by an additional layer (anti-adhesion layer) 26 suppressing the adhesion, namely precisely in the area underneath the tongue-shaped area 25b of the functional layer 25. Here too, the functional element is again stamped or cut out to provide the first film 2, see FIGS. 11A/B. This first film 2 is also suitable to be used in the production of the body 1 from FIG. 1.

(39) FIGS. 12A-C show this situation with the first film 2, which, beyond the situation represented in FIG. 11b, also has an additional layer 27 as protective layer for the electrical functional elements in the functional layer 25. If the film from FIG. 12A is back-injection molded, the situation according to FIG. 12B is obtained. The injection-molding material 3 likewise in particular adjoins the layer 26 suppressing the adhesion. In this area, however, the film 2 can be peeled off from the injection-molding material 3, with the result that the situation that arose in FIG. 12C arises, in which a tab F protrudes substantially perpendicularly from the injection-molding material 3. As represented at the start with reference to FIG. 1, such a tab F serves, in the second area 20b of the first film 2, for the contacting represented in FIG. 2 in an electrical or electronic device.

(40) With reference to FIGS. 3A/B to 6A/B on the one hand and 7A/B to 11A/B, two alternative processes for producing a film element as first film 2 have been represented. With reference to FIGS. 13A to 13D, a first process is explained below which in each case follows a production process for the first film 2. With reference to FIGS. 14A to 14D, a second such process is explained which alternatively follows these two production processes for the first film 2.

(41) An injection mold shown in FIG. 13A in the present case comprises two mold halves 9A and 9B. In the present case, both an in-mold labeling and an in-mold decoration are to take place in one step. The label is provided in the form of the above-described second film 2. This is laid on the injection mold half 9A by hand and negative pressure is applied to it, with the result that it adapts to the mold half 9A. The arrows in FIGS. 13A to 13D and 14A to 14D here show the direction of action of the negative pressure. Crossed-out arrows mean that no negative pressure is provided or no injection-molding material is introduced via an injection-molding supply line 91. In the area of the second injection mold 9B which provides a cavity 92, the second film 4 is provided, namely in the form of a film web which comprises a carrier film 41 with a decoration layer 42. The decoration layer 42 repeats itself here over the course of the carrier film. The film web is unrolled from a first roll 43a and later rolled up on a second roll 43b, the arrows pointing downwards in the figure here stand for the direction of transport.

(42) Once the first film 2 has been put in place on the first mold half 9A and the second film 4 has been put in place on the second mold half 9B, the latter optionally with the aid of a sensor (not shown in the figure) that ensures registration accuracy, a closing force F.sub.S is exerted on the two mold halves 9A/B. Negative pressure is still applied to the first film 2, but negative pressure is not applied to the second film 4. The situation shown in FIG. 13B is thus obtained.

(43) Further subsequently injection-molding material 3 is injected between the first film 2 and the second film 4 via a supply line 91, with the result that both films 2 and 4 are back-injection molded, see FIG. 13C. After the two injection mold halves 9A/B have been opened, under the application of the opening force F.sub., the finished body 1 is obtained; it is shown in FIG. 13D in the correct scale in relation to the injection-mold halves 9A/B, but at the same time on an enlarged scale.

(44) In the alternative process, the film 2 is once again placed on the first injection mold 9A, but at the same time the second film 4, likewise in the already cut-out form, is manually placed in the second mold half 9B (FIG. 14A). In a subsequent step of closing, the closing force F.sub.S is applied, wherein negative pressure is applied to the first film 2 and the second film 4 at the same time. While maintaining the negative pressure, according to FIG. 14C the injection-molding material 3 is poured in, and a body 1 is now obtained according to FIG. 14D once again after the mold halves 9A/B have been opened.

(45) After the representation of the production process for the body 1, the specification of a few important values now follows.

(46) In the layer structure shown in FIG. 15 for the first film 2, the substrate 21 consists of plastic, for example polyethylene terephthalate, polypropylene, polycarbonate, polyethylene naphthalate, polyamide and similar material, wherein the substrate 21 has a layer thickness of from 12 to 600 m, typically of from 35 to 60 m.

(47) The electrical functional layer in the present case is provided in the form of a metal layer which comprises silver, copper, aluminum, chromium or other metals or metal compounds and alloys. The layer thickness of this metal layer is between 10 and 150 nm, typically between 30 and 60 nm. The metal layer is in particular not continuous, but comprises metallic conductor traces in an either particularly regular or precisely irregular pattern, wherein the conductor traces in each case have a width of between 1 m and 40 m, preferably approximately 5 m and 20 m, and have a distance from each other of between 100 m and 5 mm, preferably of between 300 m and 1 mm. Such metallic conductor traces cannot be recognized by the human eye without an aid. The electrical functional layer 25 thereby has a transparent action, although electrical components are provided. For instance in the case of a touch panel functionality, the individual touch panels are formed by electrical conductor traces which are galvanically coupled to each other. The capacitive coupling takes place to other touch panels which are not galvanically coupled to these conductor traces and, for their part, have a plurality of metallic conductor traces which are galvanically coupled to each other one below another.

(48) The invention is not limited to the use of metallic conductor traces for providing a touch panel functionality. Any conductive and semi-conductive elements can contribute to the provision of electrical and electronic components. For example, metals can be provided in the form of nanowires (for instance made of silver, copper or gold) or nanoparticles (for instance made of silver, gold or copper), carbon nanotubes or carbon nanoparticles can be provided, or elements made of graphene can be provided. Moreover, organic conductors made of PEDOT/PSS (poly-3,4-ethylenedioxythiophene/polystyrenesulfonate) or of PAni (polyaniline) can be provided. In particular, active electrical components such as for example organic light-emitting diodes, inorganic or organic photovoltaic cells, other display elements such as for instance made of electroluminescent materials, electrochromic materials or electrophoretic materials can be provided, integrated circuits or inorganic or organic memories can be provided. All of these can equally be used within the framework of the present invention. This applies to all layer structures and sequences described in this application and all named production processes.

(49) The protective layer 27 on the electrical functional layer 25 consists for example of polyacrylate, polyvinyl chloride, polyvinyl acetate, polyurethane, polycarbonate, polyester, an ethylene vinyl acetate copolymer, a hydrocarbon resin, chlorinated polyolefin, polyvinyl alcohol, melamine resin, ketone/formaldehyde resin, polyvinylidene fluoride, epoxy resin, polystyrene, a polymeric cellulose compound, phenolic resin, polyamide, polymeric liquid crystals (LCPs), urea resin and synthetic resin or of a combination of these substances. This includes both thermally cured and radiation-cured lacquer systems.

(50) For better lacquerability and to increase the surface quality, such as e.g. the scratch resistance of the corresponding lacquer layers, various additives can be added to the base lacquer. Wetting additives, leveling additives, anti-foaming agents and fillers such as e.g. nanoscaled silicas are suitable.

(51) The layer thickness of the protective layer 27 is between 1 and 25 m, preferably between 2 and 6 m.

(52) The electrical contact reinforcement 24 consists for example of the material called carbon black or also of conductive silver in the contact area. The layer thickness typically lies between 1 and 15 m.

(53) The adhesion-promoter material 22 (primer) is shown in FIG. 15 as a single layer. This layer has a layer thickness of between 1 and 9 m, preferably of between 1 and 5 m. It preferably consists of the following material:

(54) TABLE-US-00001 Component Proportion (%) Methyl ethyl ketone 60 Butyl acetate 15 MMA polymer (Tg: 100 C.) 7 MMA/EA copolymer (Tg: 35 C.) 13 Silica (SiO2) 5

(55) Tg here is the glass transition temperature (vitrification temperature) of the respective component.

(56) In an alternative, the adhesion-promoter layer 22 can also be two-layered. In this case, it comprises, in addition to the layer just described, a further layer with a layer thickness of between 1 and 8 m, preferably of between 1 and 4 m in the following composition:

(57) TABLE-US-00002 Component Proportion (%) Methyl ethyl ketone 25 Cyclohexanone 10 Ethyl acetate 32 MMA polymer (Tg: 105 C.) 15 Acrylic acid ester (thickness = 1.102 g/cm.sup.3) 15 Photoinitiator (melting point 45-49 C.) 3

(58) The first-named layer is always located at the boundary surface between the sensor film and the injection-molding material (i.e. it touches the injection-molding material). The additional layer here is arranged such that it is located between the first-named layer and the sensor film.

(59) The layer 26 suppressing the adhesion to the injection-molding material preferably comprises a suitable wax material or the like.

(60) All thermoplastics can be used as injection-molding material 3, these are preferably polymethyl (meth)acrylate, acrylonitrile-butadiene-styrene, polycarbonate or polyamide.

(61) The injection-molding material can be colored or transparent. It can comprise fillers such as glass fibers or carbon fibers, or also be provided without fillers.

(62) The strengthening element preferably consists of plastic, wherein in particular polyethylene terephthalate, polypropylene, polycarbonate, polyethylene naphthalate are suitable, preferably in a thickness from the range of 12-150 m, particularly preferably from the range of 35-60 m.

(63) In addition to the layer structure shown in FIG. 15, in which the substrate 21 carries the adhesion-promoter layer 22 or two partial layers of the adhesion-promoter layer 22, and in which the substrate 21 is thus arranged between the electrical functional layer and the injection-molding material, there is a variant in which the situation is precisely the reverse: the substrate 21 carrying the electrical functional layer 25 and the protective layer 27 points away from the injection-molding material 3, and it is the protective layer 27 (or optionally directly the electrical functional layer 25) which carries the adhesion-promoter layer 22 (or two partial layers of the latter), and the optional anti-adhesion material in the layer 26 suppressing the adhesion. This situation is represented in FIG. 16. In this situation the arrangement of the strengthening element 23 and of the contact reinforcement 24 is also inverted.

(64) In another modification of the embodiment according to FIG. 15 the second film 2 is a multi-layer body with a plurality of electrical functional layers. In this case, there is a first substrate 21a and, on this, the electrical functional layer 25a. This in turn carries a protective layer 27, on which the second electrical functional layer 25b is located, and a second substrate 21b is located on this. Otherwise the layer structure corresponds to what was shown in FIG. 15, and the statements regarding this layer structure apply correspondingly to the embodiment according to FIG. 17.

(65) Several electrical functional layers can occur for example when capacitive components are used which are provided, not in one layer, for instance by the above-named metallic conductor traces, but rather in two layers.

(66) A first film 2 is represented in top view in FIGS. 18 and 19 in different implementations. In the case of FIG. 19, active areas can be recognized, such as for example a rotary control 201, a slide control 202 and buttons 203.

(67) The design of these elements is known per se and need not be explained in the present case.

(68) Alternatively, a touchscreen (touch panel unit) 204 can be provided, see FIG. 19. In the area 205 to be seen outside the previously identified areas, electrical connection lines are provided which lead up to the contact reinforcement 24.

(69) FIG. 20 shows the second film 2 from below with the areas which are provided with an adhesion promoter 22, those which are provided with a material 26 suppressing the adhesion, and those which furthermore comprise the strengthening element 23. With reference to FIG. 20, it becomes particularly clear how it is possible to ensure, in the later body 1 according to FIG. 1, that a tab can protrude from the injection-molding material 3, cf. also the above explanations regarding FIGS. 12a-12c.

(70) The previous description of the production process for the body 1 was based on the fact that an adhesion-promoter layer 22 and/or a layer 26 suppressing the adhesion is provided.

(71) Still further production processes are to be explained below, in which different tools are used, and in which it is ensured in a mechanical way that in the finished body 1 from FIG. 1 a tab protrudes in the second area 22b.

(72) In the embodiments described below, the second film 4 is not described. However, the processes can similarly also be provided when such a second film is to be back-injection molded according to a roll-to-roll process or manual insertion at the same time as the first film. The procedure described above in respect of FIGS. 13A-13D and 14A-14D can in each case also be provided correspondingly in conjunction with the processes described below with reference to FIGS. 21A-21H, 22A-22H, 23A-23H and 24A-24H.

(73) Alternatively or in addition to the provision of the second film 4, the first film can also carry a decoration layer.

(74) In a third process for producing the body 1 according to FIG. 1, an injection mold 9 with two mold halves 9A and 9B is used, wherein the injection mold 9 additionally has a slide 93. The injection mold half 9B here has such a shape that a film bends in the style of the second film 2 with one end. In this end, precisely the slide 93 is provided, namely the slide 93 abuts a stop 94 which is dimensioned such that exactly the typical first film 2 fits precisely between the slide 93 and a surface 95 of the second injection mold half 9B. The slide 93 has a pointed projection 96 which is suitable for separating the second film 2 from a part 97B of the injection-molding cavity which adjoins a first part 97A.

(75) While FIG. 21A shows the injection mold in the closed state, FIG. 21B shows that the mold is opened, and 21C shows that the slide 93 is extended. FIG. 21D then shows that a first film 2 is used which is adapted to the second injection mold half 9B by vacuum (see the arrows). The slide 93 is now retracted, namely by a pressure such that the second film 2 and the electrical functional layer 25 thereof is not damaged; nevertheless the pressure is high enough to separate the second film 2, in its clamped area between the slide 93 and the surface 95, from the injection-molding material.

(76) Subsequently, according to FIG. 21F, the injection mold is closed, and injection-molding material 3 is injected according to FIG. 21G. After the injection mold has been opened and the slide 93 has been extended, as shown schematically in FIG. 21H, the finished body 1 can be taken out.

(77) In a fourth process for producing the body 1, the injection mold 9 shown in FIG. 22A in the closed state is used. This has, in a second mold half 9B, two clamping jaws 98a and 98b, wherein these clamping jaws can be moved apart and back together by a collapsible core 99. With reference to FIG. 22B it becomes clear that the injection mold 9 is opened, then a self-opening of the clamping jaws 98a and 98b is brought about by moving the collapsible core 99 down, see FIG. 22C, then a second film 2 with a second section 20b can be shifted between the two clamping jaws 98a and 98b (FIG. 22D), and according to FIG. 22E the clamping jaws are closed by moving the collapsible core 99 back up, with the result that the second area 20b of the second film 2 is clamped tightly between the two clamping jaws 98a and 98b.

(78) At the same time, as indicated by the arrows in FIG. 22E, negative pressure is applied to the first film 2 in a first area 20a, with the result that it adapts to the mold half 9B. The injection mold is then closed (see FIG. 22F), injection-molding material 3 is injected, with the result that the first film 2 is back-injection molded, see FIG. 22G, and subsequently the body 1 can be removed in the case of an opened injection mold and opened clamping jaws 98a and 98b.

(79) A fifth embodiment of the process for producing the body 1 makes use of the injection molding die 9 shown in FIG. 23 enclosed state. This has an inclined ejector 901. The inclined ejector 901 has, towards the inside of the cavity 97 of the injection molding die 9, substantially the same shape that the slide 93 from FIGS. 21A-21H has. The above statements regarding the slide 93 apply correspondingly to the inclined ejector 901, except that the inclined ejector 901, as can be seen in FIG. 23C, is incorporated in the injection-mold half 9B and is extended in an inclined manner. Otherwise the steps from FIGS. 23A-23H correspond precisely to those which were described above with reference to FIGS. 21A-21H.

(80) In a sixth embodiment of the process according to the invention becoming clear with reference to FIGS. 24A-24H, a spring-loaded ejector 902 mounted in the injection mold half 9B is used. The steps of opening the injection mold, extending the ejector 902, inserting the first film 2, disconnecting its second area 20b and at the same time applying suction to the first area 20a of the latter, and subsequently back-injection molding and removing or ejecting the finished body 1 are clear with reference to FIGS. 24A-24H.

(81) In the injection molding of polymethyl methacrylate, injection pressure magnitudes of 800-1800 bar at a temperature of the injection mold halves 9A and 9B of 50-90 Celsius are usually implemented, the injection unit not shown in the figures has typical temperatures of between 250 and 280 Celsius. The injection can take place for example within one second. The cooling time can be 12 seconds. Overall, a body can be produced in a cycle of 25 seconds.

(82) In all of the previously described embodiments of the body 1, the latter is designed as a substantially flat plate, from which the tab F protrudes.

(83) FIGS. 25A and 25B show a further embodiment of the body 1 according to the invention, FIGS. 26A and 26B show a modification 1 of this body 1.

(84) In this body, a curved surface is provided, over which the first film 2 at least partially extends. In particular, the first section 20a of the first film 2 is in part guided over a curvature, see the area 20d. Here too, there is a second area 20b, which protrudes in the style of a tongue from the first area 20a, wherein the transition area 20c is precisely the area where the adhesion of the first film 2 to the injection-molding material 3 located underneath it ends. The second area 20b can thus be moved back and forth like a tab. The pivot point of this movement is the transition area 20c, which has distance d from the edge 31 which delimits the surface 30 of the injection-molding material 3 with the first film 2.

(85) In an embodiment according to FIG. 26A analogous to the shape of the injection-molding material from FIG. 25a, although the body 1 is provided with a curved surface as a whole, the first film 2 is located on a flat part of this surface. There is a first area 20a which adheres to the injection-molding material 3. In the present case, not only does a tongue-shaped part 20b protrude, but a part 20e of the actual functional area also protrudes.

(86) The three-dimensional body 1 or the three-dimensional body 1 from FIG. 25a/b or 26a/b are only intended to illustrate by way of example that quite different embodiments of the invention could be implemented.

(87) The production processes described above regarding the substantially plate-shaped body 1 can also correspondingly be implemented, with adaptation of the injection molds, in a three-dimensional body in the style of the bodies 1 and 1.

LIST OF REFERENCE NUMBERS

(88) 1, 1, 1 body 2, 2, 2 first film 3, 3, 3 plastic main material 4 second film 5 housing 6 electrical or electronic component 7 light-emitting elements 8 plug-in connection 9 injection mold 9A/B mold half 11a, 11b area at the edge of the housing part 5 20a, 20a, 20a functional area 20b, 20b, 20b contact area 20c, 20c, 20c area of surface 21, 21, 21 carrying substrate 21a first substrate 21b second substrate 22 adhesion-promoter layer 23 strengthening element 24 contact reinforcement 25 functional layer 26 suppressing layer 27 additional layer 30 surface 31, 31 delimiting edge 41 carrier layer 42 transfer layer 43a first roll 43b second roll 91 supply line 93 separate slide 94 stop 95 surface 98a, 98b clamping jaws that can be separated from each other 99 collapsible core 100 electrical device 201 rotary control 202 slide control 203 button 204 touchscreen (touch panel unit) 901 inclined ejector 902 spring-loaded ejector d, d distances F tab F.sub.S closing force F.sub. opening force