Electrical device, interlayer ply including an electrical device and methods for making said electrical device and interlayer ply

A method of making an electrical device comprising:

• (i) providing a layer of interlayer material having a first major surface and a second opposing major surface;
• (ii) positioning at least a first electrically operable component on the first major surface of the first layer of interlayer material, the first electrically operable component being mounted on a first circuit board;
• and
• (iii) providing a layer of adhesive material to cover at least a portion of the first major surface of the layer of interlayer material and at least a portion of the first electrically operable component and/or at least a portion of the first circuit board
• such that following (iii) the first electrically operable component is fixed on the layer of interlayer material by at least a portion of the layer of adhesive material,
• wherein before (iii) a flex circuit is positioned on the layer of interlayer material or the first circuit board, the flex circuit comprising a substrate having a first major surface and an opposing second major surface, the first or second major surface of the substrate of the flex circuit comprising a first electrical connector region thereon in electrical communication with a second electrical connector region on the first or second major surface of the substrate of the flex circuit by an electrically conductive track;
• wherein the flex circuit is positioned such that the second electrical connector region on the substrate of the flex circuit is in electrical communication with a first electrical connector region on the first circuit board.

A method of making an electrical device comprising:

• (i) providing a layer of interlayer material having a first major surface and a second opposing major surface;
• (ii) positioning at least a first electrically operable component on the first major surface of the first layer of interlayer material, the first electrically operable component being mounted on a first circuit board;
• and
• (iii) providing a layer of adhesive material to cover at least a portion of the first major surface of the layer of interlayer material and at least a portion of the first electrically operable component and/or at least a portion of the first circuit board
• such that following (iii) the first electrically operable component is fixed on the layer of interlayer material by at least a portion of the layer of adhesive material,
• wherein after (iii), the method includes incorporating the electrical device in an aperture in another sheet of interlayer material, wherein incorporating the electrical device in the aperture in the another sheet of interlayer material comprises providing a sheet of interlayer material having a first major surface and a second opposing major surface;
• removing at least a first portion of the sheet of interlayer material to make an aperture in the sheet of interlayer material, the aperture in the sheet of interlayer material having at least a first wall between the first and second major surfaces of the sheet of interlayer material;
• positioning at least a portion of the electrical device in the aperture;
• using bonding means to fix the electrical device to at least a portion of the first and/or second major surface of the sheet of interlayer material and/or at least a portion of the first wall of the aperture in the sheet of interlayer material.

An electrical device comprising:

• at least one electrically operable component mounted on a first circuit board, the first circuit board having a first major surface and a second opposing major surface;
• at least one layer of interlayer material having an outer major surface;
• and
• at least one layer of adhesive material having an outer major surface;
• wherein the first circuit board with the at least one electrically operable component mounted thereon is between the outer major surface of the at least one layer of interlayer material and the outer major surface of the at least one layer of adhesive material;
• further wherein the first circuit board is fixed to the layer of interlayer material by at least the layer of adhesive material;
• the electrical device has a first outer surface and a second opposing outer surface, wherein
• (a) the first outer surface of the electrical device comprises the outer major surface of the at least one layer of interlayer material and the second outer surface of the electrical device comprises the outer major surface of the at least one layer of adhesive material,
• or
• (b) the first outer surface of the electrical device comprises the outer major surface of the at least one layer of adhesive material and the second outer surface of the electrical device comprises the outer major surface of the at least one layer of interlayer material,
• wherein the electrically operable component has first and second input terminals for providing electrical power thereto and wherein first circuit board comprises a first electrical connector region, the first electrical connector region of the first circuit board being in electrical communication with the first input terminal of the electrically operable device, further wherein the electrical device comprises a flex circuit, the flex circuit comprising a substrate having a first major surface and an opposing second major surface, the first or second major surface of the substrate of the flex circuit comprising a first electrical connector region thereon in electrical communication with a second electrical connector region on the first or second major surface of the substrate of the flex circuit by an electrically conductive track, the first electrical connector region on the substrate of the flex circuit being in electrical and mechanical communication with the first electrical connector region on the first circuit board such that upon bringing the second input terminal of the at least one electrically operable component into electrical communication with a first output terminal of a suitable power supply and bringing the second electrical connector region of the flex circuit into electrical communication with a second output terminal of the suitable power supply, electrical power is provided to the at least one electrically operable component.

An electrical device comprising:

• at least one electrically operable component mounted on a first circuit board, the first circuit board having a first major surface and a second opposing major surface;
• at least one layer of interlayer material having an outer major surface;
• and
• at least one layer of adhesive material having an outer major surface;
• wherein the first circuit board with the at least one electrically operable component mounted thereon is between the outer major surface of the at least one layer of interlayer material and the outer major surface of the at least one layer of adhesive material;
• further wherein the first circuit board is fixed to the layer of interlayer material by at least the layer of adhesive material;
• the electrical device has a first outer surface and a second opposing outer surface, wherein
• (a) the first outer surface of the electrical device comprises the outer major surface of the at least one layer of interlayer material and the second outer surface of the electrical device comprises the outer major surface of the at least one layer of adhesive material,
• or
• (b) the first outer surface of the electrical device comprises the outer major surface of the at least one layer of adhesive material and the second outer surface of the electrical device comprises the outer major surface of the at least one layer of interlayer material,
• wherein the electrical device is part of an interlayer ply, the interlayer ply being suitable for joining two sheets of glass together, wherein the interlayer ply comprises a sheet of interlayer material having a first major surface and a second opposing major surface, there being an aperture in the sheet of interlayer material, the aperture having a wall extending between the first and second major surfaces of the sheet of interlayer material, the electrical device being positioned in the aperture in the sheet of interlayer material and bonded to at least a portion of the wall of the aperture and/or at least a portion of the first and/or second major surface of the sheet of interlayer material;
• and/or wherein at least one of the at least one layer of interlayer material and the at least one layer of adhesive material comprises polyvinyl butyral (PVB), a copolymer of ethylene or polyurethane.