# US 5,705,104 A · Method for embedding conductors in a structure

> Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt

- Number: US 5,705,104 A
- Document ID: US5705104A
- Status: Granted
- Kind: A
- Application number: 08/644,398
- Filed: 1996-05-10
- Granted: 1998-01-06
- Earliest claimed: 1996-05-10
- Assignees: Ford Motor Company
- Inventors: John Trublowski; Michael George Todd; Robert Edward Belke, Jr.
- Web page: https://patentgrep.com/patent/US5705104A

## CPC

- B60R 16/0207: {Wire harnesses}
- B60R: VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR

## Abstract

A method, and an article produced according to the method, for embedding conductors in a structure having a signal distribution function associated therewith such as a vehicle instrument panel. The method includes embedding a conductor in a film, and molding a material to the film such that the material and the film integrally form the structure. The method also includes attaching a connector to the integral structure so that the connector is provided in communication with the conductor.

## Claims

### Claim 1

A method for embedding conductors in a structure having a signal distribution application associated therewith, the method comprising:
embedding a conductor in a film;
molding a material to the film such that the material and the film integrally form the structure; and
attaching a connector to the integral structure so that the connector is provided in communication with the conductor.

### Claim 2 (depends on 1)

The method of claim 1 wherein the material is molded to the film such that the conductor of the film is proximate a surface of the integral structure.

### Claim 3 (depends on 1)

The method of claim 1 wherein embedding a conductor in the film includes ultrasonically heating the film.

### Claim 4 (depends on 1)

The method of claim 1 wherein molding a material to the film such that the material and the film integrally form the structure includes:
providing a molding tool;
orienting the film relative to the molding tool; and
injecting the material into the molding tool.

### Claim 5 (depends on 1)

The method of claim 1 wherein attaching a connector to the integral structure includes ultrasonically embedding a connector in the structure.

### Claim 6 (depends on 1)

The method of claim 1 wherein the material comprises a polymer.

### Claim 7 (depends on 1)

The method of claim 1 wherein the film comprises a polymer.

### Claim 8 (depends on 1)

The method of claim 1 wherein the conductor and the connector are optical.

### Claim 9 (depends on 1)

The method of claim 1 wherein the structure having a signal distribution application associated therewith comprises a vehicle instrument panel.

### Claim 10

A method for embedding electrical conductors in a structure, the method comprising:
embedding an electrical conductor in a film;
molding a polymer material about the film such that the material and the film integrally form the structure; and
embedding an electrical connector in the integral structure so that the electrical connector is provided in electrical communication with the electrical conductor.

### Claim 11 (depends on 10)

The method of claim 10 wherein the polymer material is molded about the film such that the electrical conductor of the film is embedded proximate a surface of the integral structure.

### Claim 12 (depends on 10)

The method of claim 10 wherein embedding an electrical conductor in a film includes ultrasonically heating the film.

### Claim 13 (depends on 10)

The method of claim 10 wherein molding a polymer material about the film such that the material and the film integrally form the structure includes:
providing a molding tool;
orienting the film relative to the molding tool; and
injecting the material into the molding tool.

### Claim 14 (depends on 10)

The method of claim 10 wherein the embedded electrical connector comprises an insulation displacement connector and embedding an electrical connector in the integral structure includes ultrasonically heating the structure.

### Claim 15 (depends on 10)

The method of claim 10 wherein the polymer material comprises a thermoplastic resin.

### Claim 16 (depends on 10)

The method of claim 10 wherein the polymer material comprises a thermosetting resin.

### Claim 17 (depends on 10)

The method of claim 10 wherein the film comprises a polymer.

### Claim 18 (depends on 10)

The method of claim 10 further comprising providing a further conductor on a surface of the film.

### Claim 19 (depends on 10)

The method of claim 10 wherein the structure comprises a vehicle instrument panel.