Wire controller with narrow frame and air conditioner

Abstract

The invention relates to the technical field of air conditioners, and discloses a wire controller with a narrow frame, the wire controller comprises a front shell, a rear shell, a reinforcing part and a PCB, the front shell comprises a base plate and a plurality of side plates, the base plate and the plurality of side plates are enclosed to form an installation space, the base plate is provided with a display window, and the display window is arranged in the installation space. The distance between the first side edge of the display window and the first side plate in the plurality of side plates is less than or equal to 5mm; the rear shell covers the mounting space; the reinforcing part is arranged on the inward surface of the first side plate, and a clamping groove is formed in the reinforcing part; the PCB is arranged in the installation space, the first end of the PCB is inserted into the clamping groove, and the second end of the PCB is fixed to the substrate. The invention further discloses the air conditioner.

Description

Technical Field

[0001] This application relates to the field of air conditioner technology, for example to a wired controller with a narrow bezel and an air conditioner. Background Technology

[0002] The control components of a wired controller are usually PCB control boards. Traditionally, the PCB control board is fixed to the controller housing with screws. This method adds a step to the production process, and during installation, it is necessary to avoid the electronic components inside the controller to prevent the screws from scratching the electronic components on the circuit board. This has certain design difficulties. At the same time, repeated disassembly and reassembly can also cause risks such as stripped screws and scratched components.

[0003] A wired controller is disclosed in related technology. The wired controller includes a front shell, a PCB control board, a PCB pressure plate, and a rear shell. The front shell and the rear shell are interlocked to form an accommodating space, and the PCB control board and the PCB pressure plate are disposed within the accommodating space. The PCB pressure plate is fixedly connected to the front shell, and a limiting portion is provided between the PCB pressure plate and the front shell, defining a mounting area. The PCB control board is disposed within the mounting area. By defining a mounting area between the fixedly connected front shell and the PCB pressure plate, and confining the PCB control board within the mounting area between the front shell and the PCB pressure plate, the wired controller avoids the risk of scratching electronic components caused by using screws to fix the PCB control board.

[0004] In the process of implementing the embodiments of this disclosure, at least the following problems were found in the related art:

[0005] When the bezel of the wired controller is narrow, the front shell is prone to deformation, which can affect the protection of the internal components. Summary of the Invention

[0006] To provide a basic understanding of some aspects of the disclosed embodiments, a brief summary is given below. This summary is not intended as a general commentary, nor is it intended to identify key / important components or describe the scope of protection of these embodiments, but rather as a prelude to the detailed description that follows.

[0007] This disclosure provides a wired controller and air conditioner with a narrow bezel to improve the structural strength of the wired controller's housing.

[0008] In some embodiments, the wired controller includes a front shell, a rear shell, a reinforcing part, and a PCB board. The front shell includes a base plate and a plurality of side plates, the base plate and the plurality of side plates forming an installation space. The base plate has a display window, and the distance between the first side edge of the display window and the first side plate among the plurality of side plates is less than or equal to 5 mm. The rear shell covers the installation space. The reinforcing part is disposed on the inward side of the first side plate, and the reinforcing part forms a slot. The PCB board is disposed in the installation space, with a first end inserted into the slot and a second end fixed to the base plate.

[0009] In some embodiments, the reinforcing portion includes a plurality of first reinforcing ribs, which are spaced apart along the length direction of the first side plate. The first reinforcing ribs extend along the width direction of the first side plate and are configured with notches. The notches of the plurality of first reinforcing ribs together form the slot.

[0010] In some embodiments, the reinforcing portion further includes a second reinforcing rib extending along the length direction of the first side plate.

[0011] In some embodiments, the substrate, the first side plate, the first reinforcing rib, and the second reinforcing rib are an integral structure.

[0012] In some embodiments, the reinforcing portion includes a plurality of second reinforcing ribs, which are spaced apart along the width direction of the first side plate.

[0013] In some embodiments, the ratio of the area covered by the reinforcing portion to the area of ​​the first side plate is greater than or equal to 0.1 and less than or equal to 0.9.

[0014] In some embodiments, the ratio of the thickness of the reinforcing portion to the thickness of the first side plate is less than or equal to 0.6.

[0015] In some embodiments, the distance between the upper end face of the PCB board and the first inner wall of the card slot is greater than or equal to 0.05, and the distance between the lower end face of the PCB board and the second inner wall of the card slot is less than or equal to 0.1, wherein the first inner wall and the second inner wall are two opposing walls of the card slot.

[0016] In some embodiments, the second inner wall of the slot is tilted to allow the PCB to be inserted into the slot in an tilted manner.

[0017] In some embodiments, the first inner wall of the card slot is inclined, and the width of the card slot gradually decreases from the outside to the inside.

[0018] In some embodiments, the wired controller further includes a first limiting part and a second limiting part, wherein the first limiting part is disposed on the first side plate and located at the first end of the slot; the second limiting part is disposed on the first side plate and located at the second end of the slot; the first limiting part and the second limiting part together limit the position of the PCB board.

[0019] In some embodiments, the air conditioner includes an air conditioner body and the aforementioned wired controller.

[0020] The wired controller and air conditioner with narrow bezels provided in this disclosure can achieve the following technical effects:

[0021] The wired controller provided in this embodiment has a reinforcing part on the first side plate, which allows the display window to be opened closer to the first side plate. The reinforcing part has a slot, which not only strengthens the structural strength of the first side plate, but also provides a fixing function for the installation of the PCB board.

[0022] The above general description and the description below are exemplary and illustrative only and are not intended to limit this application. Attached Figure Description

[0023] One or more embodiments are illustrated by way of example with reference to the accompanying drawings. These illustrations and drawings do not constitute a limitation on the embodiments. Elements having the same reference numerals in the drawings are shown as similar elements. The drawings are not to be scaled. And wherein:

[0024] One or more embodiments are illustrated by way of example with reference to the accompanying drawings. These illustrations and drawings do not constitute a limitation on the embodiments. Elements having the same reference numerals in the drawings are shown as similar elements. The drawings are not to be scaled. And wherein:

[0025] Figure 1 This is a schematic diagram of the structure of a wired controller provided in an embodiment of this disclosure;

[0026] Figure 2 This is a schematic diagram of the device structure of another wired controller provided in an embodiment of this disclosure;

[0027] Figure 3 This is a schematic diagram of the mounting box for a wired controller provided in an embodiment of this disclosure;

[0028] Figure 4 This is a schematic diagram of the mounting box for another wired controller provided in an embodiment of this disclosure;

[0029] Figure 5 This is a schematic diagram of the front housing of a wired controller provided in an embodiment of this disclosure;

[0030] Figure 6 This is a schematic diagram of the front housing of another wired controller provided in an embodiment of this disclosure;

[0031] Figure 7 yes Figure 6 Enlarged diagram of section B;

[0032] Figure 8 This is a schematic diagram of the structure of the rear shell of a wired controller provided in an embodiment of this disclosure;

[0033] Figure 9 This is a schematic diagram of the rear housing of another wired controller provided in an embodiment of this disclosure;

[0034] Figure 10 This is a schematic diagram of the PCB board structure of a wired controller provided in an embodiment of this disclosure;

[0035] Figure 11 This is a schematic diagram of the PCB board structure of another wired controller provided in this embodiment of the present disclosure;

[0036] Figure 12 This is a schematic diagram of the PCB board structure of another wired controller provided in this embodiment of the present disclosure;

[0037] Figure 13 This is an exploded view of a wired controller provided in an embodiment of this disclosure;

[0038] Figure 14 yes Figure 10 A cross-sectional view along line C-C.

[0039] Figure 15 yes Figure 2 A partially enlarged schematic diagram of the cross-section along line A-A;

[0040] Figure 16 This is a partially enlarged schematic diagram of the axial cross-section of the front shell along the first vent.

[0041] Figure label:

[0042] 10: Housing; 11: Display area; 12: Touch area; 100: Front housing; 101: Display window; 102: Display notch; 103: Button hole; 104: Voice control hole; 105: Disassembly port; 110: Base plate; 120: Side plate; 130: First side plate; 140: Reinforcing part; 141: First reinforcing rib; 142: Second reinforcing rib; 143: Slot; 144: First inner wall; 145: Second inner wall; 146: First limiting part; 147: Second limiting part; 151: First vent; 152: Second vent; 153: First screw post; 154: First stop rib; 155: Guide rib; 156: Protruding mating part; 200: Rear housing; 201: Receiving groove; 210: Positioning part; 2 20: Second screw post; 230: Second stop rib; 240: Reinforcing part; 251: First snap-fit; 252: Second snap-fit; 260: Protrusion; 300: PCB board; 310: Display module; 311: Backlight module; 312: Display module; 313: Driver board; 314: Display panel; 315: Indicator light; 316: Temperature and humidity sensor; 317: Positioning angle; 320: Conductive foam; 330: Power board; 400: Nameplate; 500: Mounting box; 510: Back plate; 520: Enclosure; 530: Disassembly clearance opening; 540: Edge; 541: Recessed platform; 542: Disassembly mating part; 551: First snap-fit ​​mating part; 552: Second snap-fit ​​mating part; 553: Positioning mating part; 502: Drainage channel. Detailed Implementation

[0043] To provide a more detailed understanding of the features and technical content of the embodiments of this disclosure, the implementation of the embodiments of this disclosure will be described in detail below with reference to the accompanying drawings. The accompanying drawings are for illustrative purposes only and are not intended to limit the embodiments of this disclosure. In the following technical description, for ease of explanation, several details are used to provide a full understanding of the disclosed embodiments. However, one or more embodiments may still be implemented without these details. In other cases, well-known structures and devices may be simplified in their depiction to simplify the drawings.

[0044] The terms "first," "second," etc., used in the specification, claims, and accompanying drawings of this disclosure are used to distinguish similar objects and are not necessarily used to describe a specific order or sequence. It should be understood that such data can be interchanged where appropriate for the embodiments of this disclosure described herein. Furthermore, the terms "comprising" and "having," and any variations thereof, are intended to cover non-exclusive inclusion.

[0045] In this disclosure, the terms "upper," "lower," "inner," "middle," "outer," "front," and "rear," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. These terms are primarily for better description of the embodiments of this disclosure and their implementations, and are not intended to limit the indicated devices, elements, or components to having a specific orientation, or to require them to be constructed and operated in a specific orientation. Furthermore, some of the aforementioned terms may be used to indicate other meanings besides orientation or positional relationship; for example, the term "upper" may in some cases indicate a dependency or connection relationship. Those skilled in the art can understand the specific meaning of these terms in the embodiments of this disclosure according to the specific circumstances.

[0046] Furthermore, the terms "set up," "connect," and "fix" should be interpreted broadly. For example, "connection" can be a fixed connection, a detachable connection, or an integral structure; it can be a mechanical connection or an electrical connection; it can be a direct connection or an indirect connection through an intermediate medium, or it can be an internal connection between two devices, components, or parts. Those skilled in the art can understand the specific meaning of the above terms in the embodiments of this disclosure according to the specific circumstances.

[0047] Unless otherwise stated, the term "multiple" means two or more.

[0048] In this embodiment of the disclosure, the character " / " indicates that the objects before and after it are in an "or" relationship. For example, A / B means: A or B.

[0049] The term "and / or" describes an association between objects, indicating that three relationships can exist. For example, A and / or B means: A or B, or A and B.

[0050] It should be noted that, unless otherwise specified, the embodiments and features described in the present disclosure can be combined with each other.

[0051] Combination Figure 1 As shown in Figure 16, this embodiment of the present disclosure provides a wired controller, which includes a front shell 100, a rear shell 200, a reinforcing part 140, and a PCB board. The front shell 100 includes a base plate 110 and a plurality of side plates 120. The base plate 110 and the plurality of side plates 120 enclose an installation space. The base plate 110 has a display window 101. The distance between the first side of the display window 101 and the first side plate 130 of the plurality of side plates 120 is less than or equal to 5 mm. The rear shell 200 covers the installation space. The reinforcing part 140 is disposed on the inward side of the first side plate 130 and forms a slot 143. The PCB board is disposed in the installation space. The first end of the PCB board is inserted into the slot 143, and the second end is fixed to the base plate 110.

[0052] As a control component of an air conditioner, the wired controller sends control signals to the air conditioner via wired or wireless means and receives operating status information from the air conditioner.

[0053] When the wired controller uses wireless control, it is equipped with batteries or connected to high-voltage power. High-voltage power is the opposite of low-voltage power used for control signals, and it is generally AC mains power. When the wired controller uses wired control, it is connected to the air conditioner via a wiring harness. The wiring harness includes signal wires for transmitting and receiving control signals. In some cases, the wiring harness may also include power wires for providing power input to the wired controller. If the wiring harness includes power wires, the wired controller does not need to be connected to high-voltage power.

[0054] In this embodiment, the housing 10 of the wired controller forms an installation space inside, which is used to install components such as PCB board and power board 330.

[0055] The housing 10 of the wired controller includes a front housing 100 and a rear housing 200. The front housing 100 includes a base plate 110 and a plurality of side plates 120. The base plate 110 and the plurality of side plates 120 enclose and define a mounting space. The rear housing 200 covers the mounting space. In use, the base plate 110 and the plurality of side plates 120 of the wired controller are exposed outside the housing.

[0056] The PCB board of the wired controller has a first area and a second area on its outward-facing side. The first area corresponds to the display window 101, and the second area corresponds to the touch area 12. The first area of ​​the PCB board is used to connect to the display module 310, and the second area is provided with contacts to realize the button control of the wired controller. More specifically, the PCB board is also divided into left and right areas. The left area is used to connect to the display module 310, and the right area is provided with contacts.

[0057] The display window 101 of the wired controller is positioned on the left. The distance between one long side of the display window 101 and the first side plate 130 among the multiple side plates 120 is less than or equal to 5 mm, which can increase the display area of ​​the wired controller.

[0058] When the distance between one long side of the real window and the first side plate 130 is small, the area near the first long side becomes a relatively weak area in terms of structural strength. The wire controller provided in this embodiment has a reinforcing part 140 provided in the first side plate 130. With the reinforcing part 140 provided, the first side plate 130 is not easily deformed, and the structure between the first side plate 130 and the real window is not easily deformed or broken.

[0059] Furthermore, the reinforcing portion 140 of the first side plate 130 also forms a slot 143. When installing the PCB board 300, one side of the PCB board 300 can be inserted into the slot 143, and the other end is fixed to the substrate 110 by a screw or a snap fastener.

[0060] Using the wired controller provided in this embodiment, a reinforcing part 140 is provided on the first side plate 130, so that the display window 101 can be opened to a position closer to the first side plate 130; the reinforcing part 140 is constructed with a slot 143, and the reinforcing part 140 can not only strengthen the structural strength of the first side plate 130, but also provide a fixing function for the installation of the PCB board.

[0061] Optionally, the reinforcing part 140 includes a plurality of first reinforcing ribs 141, which are spaced apart along the length direction of the first side plate 130. The first reinforcing ribs 141 extend along the width direction of the first side plate 130 and are constructed with notches. The notches of the plurality of first reinforcing ribs 141 together form a groove 143.

[0062] Multiple first reinforcing ribs 141 distributed along the length of the first side plate 130 improve the deformation resistance of the first side plate 130 in the width direction. The notches of the multiple first reinforcing ribs 141 form grooves 143, which are simple to form and have low cost.

[0063] Optionally, the reinforcing part 140 may further include a second reinforcing rib 142 extending along the length direction of the first side plate 130.

[0064] The first side plate 130 is provided with a second reinforcing rib 142. The crisscrossing first reinforcing ribs 141 and second reinforcing ribs 142 can significantly improve the deformation resistance of the first side plate 130. During the assembly and use of the wire controller, the first side plate 130 and the connection between the first side plate 130 and the substrate 110 will not deform or break due to the display window 101 being too close to the first side plate 130.

[0065] Optionally, the substrate 110, the first side plate 130, the first reinforcing rib 141, and the second reinforcing rib 142 are integral structures.

[0066] The substrate 110, the first side plate 130, the first reinforcing rib 141, and the second reinforcing rib 142 are integrally formed, resulting in a simple manufacturing process and low cost for the front shell 100. Furthermore, the integral structure further enhances the structural strength of the front shell 100 at the first side plate 130. For example, as an integral structure, the front shell 100 is made of plastic, and the substrate 110, the first side plate 130, the first reinforcing rib 141, and the second reinforcing rib 142 are integrally formed by injection molding.

[0067] Optionally, the reinforcing part 140 includes a plurality of second reinforcing ribs 142, which are spaced apart along the width direction of the first side plate 130.

[0068] Setting multiple second reinforcing ribs 142 can further improve the structural strength of the first side plate 130.

[0069] Optionally, the ratio of the area covered by the reinforcing part 140 to the area of ​​the first side plate 130 is greater than or equal to 0.1 and less than or equal to 0.9.

[0070] If the area covered by the reinforcing part 140 is too small, the improvement in structural strength of the first side plate 130 will be limited. If the area covered by the reinforcing part 140 is too large, it will lead to increased material usage and cost for the first side plate 130. A ratio between the area covered by the reinforcing part 140 and the area of ​​the first side plate 130 is between 0.1 and 0.9, which allows the first side plate 130 to balance structural strength and economy.

[0071] Optionally, the ratio of the thickness of the reinforcing part 140 to the thickness of the first side plate 130 is less than or equal to 0.6.

[0072] The thickness of the reinforcing part 140 refers to the height by which the reinforcing part 140 protrudes outward from the first side plate 130, and is in the same direction as the thickness direction of the first side plate 130. The ratio of the thickness of the reinforcing part 140 to the thickness of the first side plate 130 is less than or equal to 0.6, which can give the first side plate 130 a certain structural strength and will not cause the reinforcing part 140 to occupy too much space inside the installation space.

[0073] Optionally, the distance between the upper end face of the PCB board and the first inner wall 144 of the slot 143 is greater than or equal to 0.05, and the distance between the lower end face of the PCB board and the second inner wall 145 of the slot 143 is less than or equal to 0.1, wherein the first inner wall 144 and the second inner wall 145 are two opposing walls of the slot 143.

[0074] One end of the PCB board is inserted into the slot 143, which has a first inner wall 144 near the outside and a second inner wall 145 near the inside. The upper surface of the PCB board faces outward, and the distance between the outward surface and the first inner wall 144 of the slot 143 is greater than or equal to 0.05 mm, providing sufficient space for the insertion of the PCB board and allowing for thermal expansion and contraction. The lower surface of the PCB board faces inward, and the distance between the inward surface and the second inner wall 145 of the slot 143 is less than or equal to 0.1 mm, resulting in a smaller clearance after the PCB board is inserted into the slot 143, which is beneficial for the reinforcement 140 to fix the PCB board.

[0075] Optionally, the second inner wall 145 of the card slot 143 is tilted to allow the PCB to be inserted into the card slot 143 in an tilted position.

[0076] The second inner wall 145 of the slot 143 is inclined, allowing the PCB board to be tilted to a certain extent when inserted. This design makes it easier for the user to insert one end of the PCB board into the slot 143.

[0077] Optionally, the first inner wall 144 of the slot 143 is inclined, and the width of the slot 143 gradually decreases from the outside to the inside.

[0078] The width of the slot 143 gradually decreases from the outside to the inside, providing a large installation margin when installing the PCB board and facilitating the assembly of the wired controller.

[0079] Optionally, the wired controller further includes a first limiting part and a second limiting part, wherein the first limiting part is disposed on the first side plate 130 and located at the first end of the slot 143; the second limiting part 147 is disposed on the first side plate 130 and located at the second end of the slot 143; the first limiting part 146 and the second limiting part together limit the position of the PCB board.

[0080] The first limiting part and the second limiting part of the wired controller are located at both ends of the slot 143, so that the end position of the PCB board is limited and guided when it is inserted into the PCB board.

[0081] Optionally, a button hole 103 is provided on the outward side of the housing 10, and a conductive foam 320 is connected at one end to a contact and passes through the button hole 103 to elastically press against the inward side of the nameplate 400.

[0082] One end of the conductive foam 320 is connected to the contact point on the PCB board, and the other end passes through the button hole 103, pressing against the inward side of the nameplate 400 in an elastic state. The conductive foam 320 is conductive and is the core component connecting the operation of the nameplate 400 and the signal on the PCB board; the conductive foam 320 also has elastic properties, ensuring stable contact with the nameplate 400 and the contact point when not pressed, triggering a signal through deformation after pressing, and automatically resetting after being released.

[0083] The user presses the area corresponding to the function on the nameplate 400; after being pressed, the nameplate 400 is squeezed into the housing 10, pushing the conductive foam 320 that is in contact with it; the conductive foam 320 is compressed and deformed, increasing the contact pressure between it and the PCB board contacts or achieving circuit conduction through deformation, generating an electrical signal. The contacts on the PCB board receive this electrical signal and interpret it into a corresponding control command through internal circuitry; the wired controller sends the interpreted control command to the air conditioner via wired or wireless means; after the user releases the press, the conductive foam 320 returns to its original shape due to its own elasticity, the nameplate 400 resets accordingly, the conduction state between the conductive foam 320 and the contacts is broken, and the wired controller returns to the ready-to-trigger state.

[0084] The conductive foam 320 connects the PCB board contacts and the nameplate 400 simultaneously via elastic pressure. On one hand, when not pressed, its own elasticity maintains stable contact, preventing trigger failure due to component assembly gaps. On the other hand, the deformation during pressing buffers the pressure, preventing damage to the PCB board contacts from hard contact and ensuring the instantaneous conduction of the signal. It automatically resets upon release, significantly extending the button's lifespan. The internal mounting space of the housing 10 provides enclosed protection for core components such as the PCB board and power board 330, preventing direct intrusion of dust and moisture. Simultaneously, the nameplate 400 completely covers the button hole 103, further blocking external impurities from entering the gap between the conductive foam 320 and the button hole 103. This design reduces malfunctions such as contact oxidation and foam failure caused by environmental factors (e.g., humidity, dust accumulation), improving the adaptability of the wired controller in humid environments such as kitchens and bathrooms. The Nameplate 400 integrates multiple button functions onto a single external plane, eliminating physical button protrusions. This results in a cleaner appearance and eliminates the need for users to identify raised buttons; they can operate the device simply by pressing the corresponding function area. This is especially suitable for the elderly and children, reducing the learning curve. Each foam pad corresponds to a single contact point, and the elastic deformation range of the foam is controllable. When a user presses a specific area, only the foam at that location is compressed and conducts a signal, while adjacent foam pads remain unaffected. This effectively avoids the problem of accidentally triggering multiple functions by pressing a single button, improving control accuracy.

[0085] The housing 10 of the wired controller has a button hole 103, and conductive foam 320 is located inside the button hole 103. One end of the conductive foam 320 contacts the contact point on the PCB board, and the other end contacts the inward side of the nameplate 400. When the user presses the corresponding area of ​​the nameplate 400, the conductive foam 320 is compressed, and the end of the conductive foam 320 connected to the PCB board generates an energized signal.

[0086] The wired controller provided in this embodiment utilizes the conductive foam 320, which possesses both elastic and conductive properties. This allows it to compensate for assembly gaps through elasticity, ensuring stable button contact and preventing trigger failures. It also buffers pressing pressure, protecting the PCB board contacts and nameplate 400, extending component lifespan. Furthermore, the one-foam-one-contact design eliminates accidental operation. The enclosure 10's design, which seals the installation space, and the nameplate 400's full coverage of the button holes 103, prevents the intrusion of dust, moisture, and other impurities, making the wired controller suitable for damp and dusty environments such as kitchens and bathrooms, reducing malfunctions. The nameplate 400's flat, non-protruding design not only creates a simple appearance that complements various home styles but also reduces the learning curve for elderly and children users and facilitates cleaning. Simultaneously, this structure reduces the number of components in traditional buttons, simplifying the production and assembly process. Later repairs only require replacing the corresponding conductive foam 320, improving production and maintenance efficiency.

[0087] Optionally, the initial length of the conductive foam 320 is L1, and the length of the conductive foam 320 after installation on the wired controller is L2. Then, the initial length of the conductive foam 320 and the length of the conductive foam 320 after installation satisfy the following relationship: 0.9*L1≥L2≥0.7*L1; where the initial length of the conductive foam 320 is L1, and the length of the conductive foam 320 after installation is L2.

[0088] If L2 < 0.7L1, two problems will arise: First, the foam will be under extreme compression for a long time, causing its elasticity to decay rapidly. This will result in a gap where the foam cannot press firmly against the nameplate 400 when not pressed, leading to loose contact between the contacts and the foam and unstable signal transmission. Second, excessive compression of the foam may reduce its conductivity due to internal structural damage (such as broken conductive particles), even causing a failure to conduct signals when pressed. Setting the lower limit of L2 to 0.7L1 essentially preserves a basic elastic margin for the foam, ensuring that it can still firmly press against the PCB board contacts and the nameplate 400 after installation, maintaining stable physical contact and a conductive path, thus preventing poor contact at its source.

[0089] If L2 > 0.9L1 (i.e., the foam compression is too small), the contact pressure between the foam and the PCB board contacts / nameplate 400 will be insufficient. When not pressed, slight vibrations (such as wall vibrations or accidental touches) may cause the foam to briefly separate from the contacts, resulting in false alarms or signal interruptions. When pressed, the user needs to press a larger distance (the distance from L2 to full conduction) to ensure sufficient contact between the foam and the contacts and to conduct the signal, resulting in a significant trigger delay (no response when pressed, requiring force to press all the way down), severely impacting the user experience. Setting the upper limit of L2 to 0.9L1 ensures that the foam and contacts maintain a certain level of contact through appropriate pre-compression.

[0090] When L2 is between 0.7L1 and 0.9L1, the elasticity of the foam is in the optimal response range. When the user presses, the force (pressing pressure) required is moderate (neither pressing hard nor triggering with a light touch). At the same time, the foam rebounds at a uniform speed after pressing, giving the user a clear tactile feedback when pressed and a return to its original position when released, avoiding the confusion of whether the press was successful due to ambiguous pressing pressure.

[0091] In summary, the design of conductive foam with 3200.9L1≥L2≥0.7L1 is the optimal choice from three dimensions: functional reliability, user experience, and production feasibility. It ensures the long-term stable operation of the wired controller, optimizes the operating feel, and reduces the difficulty of production and assembly. It is a key parameter design to ensure the core performance of the wired controller.

[0092] Optionally, the button hole 103 is a flared opening from the inside out.

[0093] In traditional straight-wall button holes 103, the inner and outer diameters are the same. When the conductive foam 320 is inserted from the inside to the outside, it needs to be precisely aligned with the hole diameter (if the foam diameter is close to the hole diameter, it is easy to get stuck in the hole due to slight deviation). However, the flared structure with a smaller inner side and a larger outer side forms an outwardly expanding guide slope. When the foam is inserted from the inside (small hole end), even if there is a slight deviation in the initial alignment, it can slide naturally along the slope to the outside (large hole end) without repeated adjustments. This greatly improves the assembly speed and is especially suitable for automated assembly lines (reducing the accuracy requirements of robotic arm alignment).

[0094] Conductive foam 320 is elastic and may undergo slight deformation due to compression during assembly (such as a temporary increase in diameter). If the diameter of the straight-walled hole matches the diameter of the foam too tightly, the deformed foam is easily scratched or torn by the hole wall when passing through, leading to functional failure. The large diameter of the hole on the outside of the flared opening can accommodate the deformed part of the foam, avoiding hard compression or scratching of the foam by the hole wall, reducing the component loss rate during assembly (improving the yield rate).

[0095] When the user presses the nameplate 400, the conductive foam 320 will compress and deform into the housing 10 (the diameter may expand slightly). The hole wall of the traditional straight wall hole is a vertical surface. If the diameter of the foam after deformation is close to or exceeds the hole diameter, it is easy to rub against the hole wall or even get stuck, resulting in a failure to rebound smoothly after pressing (resulting in button sticking). The large diameter of the outer side of the flared mouth provides sufficient space for the radial deformation of the foam. Even if the diameter of the foam increases due to compression, it will not contact the hole wall, ensuring a smooth pressing and rebound process and avoiding trigger delay or reset failure caused by sticking.

[0096] After pressing and releasing, the conductive foam 320 needs to rely on its elasticity to return to its initial state (realigning with the contacts on the PCB board); the inner small hole end of the flared opening matches the initial diameter of the foam, while the tapered channel formed by the outer large diameter will play a guiding role when the foam rebounds. During the rebound process, the foam will naturally converge inward (towards the small hole end) along the inclined surface of the flared opening, and finally return to the position precisely aligned with the contacts, avoiding misalignment between the foam and the contacts due to rebound offset.

[0097] The opening edge of a traditional straight-wall hole is at a right angle. If the nameplate 400 is slightly offset during installation, it is easy to make point contact with the right-angle edge of the opening, resulting in a slight bulge in the corresponding area of ​​the nameplate 400 (affecting the appearance and causing uneven feel when pressing). On the other hand, the opening edge of the flared opening is an outward-expanding bevel, which has a larger contact area with the nameplate 400 (changing from point contact to surface contact). Even if the nameplate 400 is slightly offset, it can maintain a flat fit through the buffering effect of the bevel, avoiding local bulges.

[0098] When the user presses the nameplate 400, the pressing force is transmitted through the nameplate 400 to the conductive foam 320, and at the same time, it will generate local stress on the contact edge between the nameplate 400 and the housing 10. The right-angled edge of the straight wall hole is prone to stress concentration around the hole opening (causing cracks in the nameplate 400 after long-term use), while the beveled edge of the flared opening can disperse the stress to a larger contact area, reduce the problem of excessive local stress on the nameplate 400, and extend its service life.

[0099] Optionally, the button hole 103 includes a first segment and a second segment from the inside out, wherein the tilt angle of the second segment is greater than that of the first segment.

[0100] The first section, located close to the interior of the housing 10 (near the PCB board contacts), has a gentle tilt angle (e.g., 5°–10°) that limits the range of motion of the conductive foam 320 to a small area. During assembly, after the foam enters the first section from the inside, the gentle slope prevents significant displacement of the foam, guiding it to always align with the PCB board contacts (avoiding secondary adjustments due to excessively steep tilt). Compared to a single flared opening (with a consistent tilt angle throughout, resulting in low internal positioning accuracy if the angle is steep), the gentle design of the first section provides an initial positioning channel for the foam, ensuring the alignment accuracy between the foam and the contacts after assembly and reducing the risk of button malfunction due to misalignment. The second section is located near the outer side of the housing 10 (in contact with the nameplate 400). Its larger tilt angle (such as 15°–30°) allows the aperture of the hole to expand rapidly. When the foam passes through the first section and enters the second section, the large expansion space formed by the steep slope can accommodate the elastic deformation of the foam (such as the increase in diameter caused by slight compression during assembly), avoiding friction between the foam and the hole wall. At the same time, the steep slope has a shorter guiding distance and a faster expansion speed, allowing the foam to quickly pass through the second section and press against the nameplate 400. Compared with a single, gentle flared opening (long path and low efficiency), this significantly improves the assembly speed, especially suitable for the rapid feeding requirements of automated production lines.

[0101] When a user presses the button, the conductive foam 320 needs to complete the entire process of compression deformation, signal transmission, and elastic reset. The two-stage inclined structure, through segmented space optimization, solves the problems of limited deformation and reset offset that may exist with a single horn opening: When the nameplate 400 is pressed, the conductive foam 320 will compress inward and expand radially (increasing its diameter) due to compression. The large aperture space created by the steep incline of the second stage can fully accommodate the radial expansion of the foam—even if the foam expands significantly, it will not contact the second stage hole wall (avoiding pressing jams caused by friction); while the small aperture of the gently inclined first stage can limit excessive offset of the foam (ensuring that it is always aligned with the contact point during compression and will not deviate from the signal transmission path due to expansion). Compared with a single horn opening (if the angle is gentle, the outer aperture is small, and the foam expansion is prone to jamming; if the angle is steep, the inner aperture is large, and the foam compression is prone to offset), the two-stage structure provides dual protection against jamming on the outside and offset on the inside, ensuring a smooth pressing feel and accurate signal transmission. After being pressed and released, the conductive foam 320, relying on its elasticity, needs to return from its compressed state to its initial state and realign with the contacts. At this point, the first gently sloping section forms a gradual guiding path—as the foam rebounds, it slowly converges inward along the gentle slope, preventing excessively fast rebound or directional deviation due to an overly steep slope; while the second steep slope, with its large aperture, does not obstruct the rebound process. Ultimately, guided by the first section, the foam precisely returns to its aligned position with the contacts, preventing button malfunction due to reset misalignment (such as the foam rebounding off-center, resulting in no response when pressed).

[0102] When the nameplate 400 covers the button hole 103, its inner side contacts the steep slope of the second section. Compared to a single, gentle flared opening (where the contact area between the hole and the nameplate 400 is small, and uneven fitting can easily lead to local bulges), the steep slope of the second section has a larger inclination angle and a larger edge area of ​​the hole, which increases the contact area between the nameplate 400 and the hole, reduces local bulges of the nameplate 400 caused by point contact, ensures that the nameplate 400 fits flat overall, and improves the consistency of appearance.

[0103] When the user presses the nameplate 400, the pressure is transmitted through the nameplate 400 to the conductive foam 320, and at the same time, local stress is generated on the edge of the nameplate 400 that contacts the orifice. The large contact area of ​​the second steep slope can disperse the stress over a wider range (rather than concentrating it on a single point), preventing the nameplate 400 from cracking due to excessive local stress after long-term use; while the first gentle slope, because it is located inside the housing 10, does not directly contact the nameplate 400 and will not affect the force on the nameplate 400.

[0104] In summary, the design of the button hole 103, consisting of a first segment and a second segment (with the second segment having a greater tilt angle than the first segment), represents a refined upgrade of the single horn opening. By using segmented and differentiated tilt angles, it achieves more precise and balanced optimization in four dimensions: assembly efficiency, trigger stability, structural strength, and nameplate lifespan of 400. This not only solves the shortcomings of the single horn opening in terms of positioning accuracy and structural strength but also retains its core advantages of protection and guidance, further enhancing the overall performance and reliability of the wired controller.

[0105] Optionally, the tilt angle of the flared mouth is greater than or equal to 10° and less than or equal to 45°; or, the tilt angle of the second segment of the flared mouth is greater than or equal to 10° and less than or equal to 45°.

[0106] The core function of the flared opening is to provide assembly guidance for the conductive foam 320 and to provide space for pressure deformation. An angle range of 10°–45° ensures that these two functions are implemented efficiently, avoiding the defects of extreme angles: if the tilt angle is <10° (e.g., 5°), the flared opening will approach a straight-walled hole, losing its core advantage of outward expansion, leading to two major problems: if the angle is too small, the hole diameter expands slowly, and when the conductive foam 320 is inserted from the inside, it needs to be precisely aligned with the center of the hole to pass through (no different from a straight-walled hole). During automated assembly, it is easy to get stuck due to slight deviation, failing to achieve the goal of rapid guidance and insertion; even with manual assembly, the position needs to be repeatedly adjusted, significantly reducing efficiency. The radial expansion of the conductive foam 320 during pressing cannot be effectively accommodated—if the angle is too small, the difference between the outer and inner hole diameters is small, and the foam is easy to rub against the hole wall after expansion, resulting in problems such as pressing stuck and poor rebound, affecting the operating feel and trigger stability.

[0107] Setting the lower limit to 10° ensures a clear expansion gradient at the flared opening: it can quickly guide the foam during assembly and provide ample space for the foam to expand when pressed, thus fundamentally realizing the functional value of the flared opening.

[0108] If the tilt angle is greater than 45° (e.g., 60°), the flared opening will cause new functional defects due to excessive expansion: If the angle is too large, the outer aperture will expand drastically, and the conductive foam 320 will easily shift due to the excessive expansion space (e.g., tilting to one side), leading to misalignment between the foam and the PCB board contacts after assembly, resulting in button malfunction. Even with manual adjustment, it is difficult to guarantee alignment accuracy, increasing rework rates. During rebound, the over-expanded hole walls cannot provide effective guidance for the foam—the foam is prone to deviating from its initial position during rebound, failing to accurately return to its original position above the contacts, leading to unresponsive buttons after prolonged use.

[0109] Setting the upper limit to 45° allows for a balance between expansion space and positioning accuracy: it satisfies the space requirements for foam assembly and deformation, while limiting foam offset through a moderate expansion gradient, ensuring assembly alignment accuracy and reset stability.

[0110] Although the outer aperture is enlarged due to the tilt, the angle of 10°-45° allows the aperture to gradually shrink (from the outer large aperture to the inner small aperture): large particles of impurities (such as dust and fibers) will be blocked by the inner small aperture even if they enter the outer aperture, and will not be able to enter the shell 10 to contaminate the PCB board.

[0111] Moisture in humid environments tends to condense on the pore walls. The slope in this angle range can guide the moisture to flow downwards naturally (instead of accumulating inside the pores), reducing the risk of moisture penetration.

[0112] If the angle is greater than 45°, the outer opening is too large, allowing large particles of impurities to enter directly; if the angle is less than 10°, the gentle slope allows moisture to accumulate easily, both reducing protective performance. The elastic contact pressure between the conductive foam 320 and the nameplate 400 provides another layer of protection—an angle of 10°–45° ensures that the foam, after passing through the flared opening, can form uniform contact pressure with the nameplate 400.

[0113] In summary, limiting the tilt angle of the horn opening (or the second segment in a two-section design) to 10°≤angle≤45° is the optimal design in terms of comprehensive functional effectiveness, structural strength, production feasibility, and scenario protection. It ensures that the horn opening can efficiently perform its guiding and deformation space functions, guarantees the shell strength and production efficiency, and adapts to the protection requirements of multiple scenarios. This is a key parameter selection for standardization and high reliability in the structural design of wired controllers.

[0114] Optionally, the housing 10 is provided with guide ribs 155 extending inward along the periphery of the button hole 103, and the conductive foam 320 is located in the cylindrical space enclosed by the guide ribs 155.

[0115] The core function of conductive foam 320 relies on the precise alignment of the PCB board contacts and nameplate 400. The cylindrical space enclosed by guide ribs 155 essentially creates a dedicated positioning channel for the foam, fundamentally avoiding the risk of positional misalignment in traditional ribless designs: the inner diameter of the cylindrical space formed by the guide ribs 155 precisely matches the outer diameter of the conductive foam 320 (with minimal gap) – after installation, the foam is tightly constrained by the ribs, preventing radial (perpendicular to the foam axis) displacement. This design completely solves two major pain points:

[0116] During assembly, the foam does not require repeated calibration by manual labor or robotic arms. It can be directly placed into the cylindrical space to accurately align with the PCB board contacts, greatly improving assembly efficiency (especially on automated production lines) and avoiding rework due to button malfunction caused by misalignment.

[0117] When in use, when the foam is compressed and deformed by pressing the nameplate 400, the ribs can prevent the foam from shifting laterally due to compression (such as tilting to one side), ensuring that the foam is always aligned with the contact point and that signal transmission is uninterrupted (avoiding the problem of foam shifting and intermittent signal transmission when pressed in traditional ribless designs).

[0118] Guide ribs 155 extend axially along the button hole 103 (in the direction of foam compression / reset), forming a straight channel. When the user presses the button, the foam can only be compressed along the axial direction defined by the ribs; after releasing, the foam elastically rebounds along the axial direction, preventing tilting and resetting due to uneven rebound force. Compared to designs without ribs where the foam may compress obliquely or reset at an angle, this structure ensures consistent stroke and uniform force for each press, providing users with a stable pressing feedback feel (e.g., consistent pressing force and rebound speed), avoiding misjudgments of whether the operation was successful due to fluctuations in feel.

[0119] In the ribless design, when the nameplate 400 is pressed, the force on the foam is concentrated in the local area in contact with the nameplate 400. Long-term repeated compression can easily lead to collapse and detachment of the conductive layer in this area. However, the cylindrical space enclosed by the guide ribs 155 can indirectly transmit some of the pressing force through the ribs. The pressing force of the nameplate 400 is first transmitted to the foam, and then distributed to the surrounding ribs through the foam. This avoids excessive pressure on a single area of ​​the foam and reduces the risk of local damage (especially for the softer and less elastic conductive foam 320 material).

[0120] After prolonged periods of inactivity or frequent use, conductive foam 320 is prone to natural sagging and deformation due to its own weight or repeated deformation (especially when the wireless controller is installed at an angle), leading to poor contact with the contacts. The cylindrical space formed by the guide ribs 155 can support the outer periphery of the foam. Even with long-term use, the foam will not deform due to external forces or its own characteristics, always maintaining stable contact with the contacts and nameplate 400, slowing down the rate of elasticity decay, and extending the service life of the foam (actual tests show that it can increase the number of button cycles by more than 30%).

[0121] The guide rib 155 extends inward along the periphery of the button hole 103, effectively adding a ring-shaped reinforcing rib to the button hole 103 area of ​​the housing 10. When the housing 10 is subjected to lateral external force (such as falling or impact), the rib can disperse the impact force, preventing stress concentration and cracking around the button hole 103 (in traditional ribless designs, the edge of the button hole 103 is prone to direct breakage due to impact). The reinforcing effect of the guide rib 155 is especially crucial for thin-walled housings 10 (using thinner plastic material for lightweight design), allowing the housing 10 to find a balance between lightweight and strength.

[0122] If the wired controller is accidentally dropped, the unrestrained foam may come out of the button hole 103 due to inertia and hit the internal PCB board, power board 330 and other components, causing the components to fall off or be damaged. However, the cylindrical space enclosed by the guide ribs 155 can firmly fix the foam. Even if it is subjected to a violent impact, the foam can only move slightly within the cylindrical space and cannot hit the internal components, thus indirectly protecting the safety of the core circuit.

[0123] When the robotic arm grasps the conductive foam 320, the cylindrical space enclosed by the guide ribs 155 can serve as a visual positioning marker (the outline of the ribs is identified by machine vision), allowing the robotic arm to quickly determine the installation position of the foam without relying on complex coordinate calibration, thus reducing assembly and debugging time.

[0124] In the ribless design, if the robotic arm is slightly tilted when placing the foam, the foam may get stuck in the button hole 103 (requiring readjustment). However, the straight channel formed by the guide ribs 155 can guide the foam to be placed vertically. Even if there is a slight angular deviation in the robotic arm, the ribs can correct the posture of the foam, avoid jamming, and improve the yield rate of automated assembly (from 95% to over 99%).

[0125] In summary, the design of setting guide ribs 155 around the button hole 103 of the housing 10 is an upgrade of the traditional structure from four dimensions: functional reliability, structural strength, protective performance, and production efficiency. It not only solves the core problems of the positioning and life of the conductive foam 320 through precise constraints, but also strengthens the strength and dustproof and waterproof capabilities of the housing 10. At the same time, it is adapted to the needs of automated mass production and is a key optimization solution with low cost and high returns in the structural design of wired controllers.

[0126] Optionally, the height of the guide rib and the length of the conductive foam in use satisfy the following relationship: h / H≥0.67; where h is the height of the guide rib and H is the length of the conductive foam 320 in use.

[0127] During pressing, the conductive foam 320 compresses into the housing 10. If the height of the stop ribs is insufficient (h / H < 0.67), the constraint depth of the ribs on the foam is insufficient, which can easily lead to excessive tilting of the upper part of the foam (the area not constrained by the ribs), causing two major problems: First, the tilting of the foam reduces its contact area with the PCB board contacts (or even causes partial detachment), potentially resulting in intermittent signal interruptions during pressing (e.g., trigger failure due to slightly different pressing pressure). Second, a h / H ratio ≥ 0.67 ensures that the ribs cover more than 2 / 3 of the foam's usable length—even when the foam is compressed to its shortest state (when pressed to the bottom), a large portion of its length is still constrained by the ribs, preventing overall tilting and ensuring stable contact with the contacts. Third, foam tilting leads to differences in pressing pressure feedback in different directions (e.g., pressing the left side requires more effort, while the right side is easier), resulting in a fragmented user experience. Fourth, when the rib depth is sufficient, the foam is constrained in all directions and can only be compressed uniformly along the axial direction, ensuring a consistent pressing feel in different areas (no difference in pressing pressure or travel feedback).

[0128] When conductive foam 320 is pressed, it needs to rebound to its initial position. Insufficient rib height will weaken the guidance of the rebound process, resulting in reset deviation.

[0129] If h / H < 0.67, the ribs only cover a small part of the lower part of the foam. When the foam rebounds, the upper part is prone to shift to one side due to inertia (especially when the pressing position is skewed), making it impossible to accurately align with the contact point. Long-term use may cause the button to malfunction.

[0130] When h / H≥0.67, the ribs cover most of the length of the foam. During the rebound process, the foam will be guided by the ribs throughout and return to its original position in a straight line along the axis. Even if there is a slight deviation when pressing, it can return to the center position under the constraint of the ribs, ensuring the alignment accuracy with the contact point.

[0131] The elastic decay of conductive foam 320 mainly stems from excessive local deformation. Sufficient rib height can mitigate this process by dispersing stress: Without ribs or with excessively short ribs, the deformation during foam compression is concentrated in the lower part (the area in contact with the contacts). Repeated compression over a long period leads to rapid loss of elasticity in this area (collapse). When h / H ≥ 0.67, the ribs constrain most of the foam's length, and the compression deformation is evenly distributed across the rib-covered area (rather than concentrated at a single point), reducing local stress overload and significantly extending the foam's elastic life (actual measurements show an increase of over 50% in the number of compression cycles). Rib height is not always better the higher it is (h / H = 1 provides the strongest constraint, but leads to assembly difficulties). The lower limit of 0.67 represents a balance between constraint effectiveness and assembly difficulty.

[0132] If h / H < 0.67, the constraint is insufficient and the tilting and offset problems cannot be solved; if h / H ≥ 0.67, it can provide effective constraint and also reserve an unconstrained area at the top (1 / 3 of the length not covered by the rib) for the foam. During assembly, the foam can first quickly align with the rib entrance through the unconstrained area at the top, and then slide into the bottom along the rib, avoiding assembly jamming caused by the rib being too high (such as h / H = 0.9) (which requires extremely high precision alignment to insert).

[0133] In summary, the h / H≥0.67 design, with sufficient depth constraints, ensures stable pressing, accurate resetting, and extended lifespan of the conductive foam 320 while also considering assembly feasibility. It represents the optimal ratio for balancing functional reliability and production efficiency.

[0134] Optionally, there is a gap between the guide rib and the PCB board.

[0135] In button structure design, the reserved gap between the guide ribs and the PCB board is not simply a matter of spatial redundancy, but a necessary design based on three core requirements: assembly tolerance, avoidance of interference, and adaptation to environmental deformation. It can effectively solve multiple potential problems in the production and use process. The specific functions are as follows: If the zero gap design is used, the corresponding positions of the guide ribs and the PCB board must be absolutely aligned during assembly (accuracy requirement within ±0.05mm), otherwise they cannot fit together; however, with the reserved gap, assembly personnel or automated equipment do not need to be perfectly aligned, and the ribs can adaptively adjust their positions within the gap range, which significantly improves assembly efficiency (actual tests show that it can shorten the assembly time by more than 30%).

[0136] Both the guide ribs and the PCB board are rigid components (the housing is mostly made of ABS / PC plastic, and the PCB board is made of fiberglass). If they are in direct contact, they are prone to rigid interference due to external forces or vibrations, leading to structural damage. When the button is pressed, the 320mm conductive foam compression indirectly transmits a small impact force to the stop ribs (especially in cases of heavy pressing). If the ribs are in rigid contact with the PCB board, the impact force will be directly transmitted to the PCB board. Long-term repeated action may cause the solder joints on the PCB board to fall off (such as the metal contact solder joints in contact with the foam). The reserved gap can form a buffer space, and the impact force is absorbed by the gap, preventing it from being transmitted to the PCB board. If the product is used in scenarios with continuous vibration, such as automotive or home appliances, the zero-gap ribs and the PCB board will generate continuous friction due to vibration: on the one hand, it will wear down the bottom of the ribs (leading to a reduction in rib height and a weakening of the constraint effect); on the other hand, the plastic debris generated by friction may fall onto the surface of the PCB board, causing a short circuit risk. The reserved gap can completely avoid this friction and protect the integrity of the components.

[0137] The pressing function of conductive foam 320 relies on a complete compression-rebound stroke. The gap design directly affects the effectiveness of the foam's stroke: if there is zero gap between the guide ribs and the PCB board, the bottom of the ribs will directly adhere to the PCB board surface, causing the bottom space of the conductive foam 320 to be completely occupied. When pressing, the foam can only be axially compressed within the cylindrical space enclosed by the ribs, but there is no buffer space at the bottom. Excessive compression may cause the foam to lose its elasticity (resulting in dead keys). The reserved gap (usually matched with the foam compression amount, such as 0.1~0.3mm for a foam compression amount of 0.3mm) can provide redundant space for the bottom deformation of the foam, ensuring that the foam can be fully compressed to the designed stroke (such as 0.5mm) when pressed, while avoiding direct hard contact with the PCB board and protecting the elastic structure of the foam.

[0138] The gap between the guide ribs and the PCB board is not necessarily better the larger it is. It needs to be determined comprehensively based on the product size, material, and usage environment. The general design principle is: gap value range: usually 0.1~0.5mm (0.1~0.2mm for small button structures, 0.3~0.5mm for large buttons / vehicle structures); matching relationship: the gap value should be less than the compression amount of conductive foam 320 (to avoid the bottom of the foam falling into the gap when it rebounds, causing displacement), and greater than the maximum tolerance superposition value between the housing 10 and the PCB board (to ensure assembly error tolerance).

[0139] Optionally, the guide ribs form a tapering hole from the inside out.

[0140] Designing the guide ribs as tapered holes from the inside out (i.e., the inner diameter of the hole is larger and the outer diameter is smaller, forming an inwardly expanding conical structure) represents a refined upgrade to the guiding and constraint functions. This design achieves superior performance in three dimensions—assembly guidance of conductive foam 320, pressing stability, and structural adaptability—through gradient spatial constraints. Specific technical effects are as follows: The assembly of conductive foam 320 involves inserting it from the outside of the housing 10, passing it through the rib holes, and finally aligning it with the PCB board contacts. The tapered hole structure, with its loose inner side and tight outer side, perfectly adapts to the different requirements of this process: the inner side (closer to the PCB board) of the tapered hole has a larger diameter, providing ample tolerance for the initial insertion of the conductive foam 320—even if the foam is slightly tilted or misaligned during assembly, it can smoothly enter the large-diameter inner area without requiring high-precision alignment (compared to straight holes or outwardly expanding holes, assembly efficiency is improved by more than 40%). This design is particularly important for automated assembly: when the robotic arm grasps the foam, no strict positional calibration is required; the foam can be automatically received through the large inner diameter aperture, significantly reducing assembly delays and rework. As the foam moves inward, the diameter of the tapered hole gradually decreases (the outer aperture precisely matches the foam diameter), naturally guiding the foam towards the center, ultimately achieving precise alignment with the PCB board contacts. This process of first loosely receiving and then precisely positioning solves the problem of difficult insertion of straight-hole designs and avoids the insufficient positioning accuracy of purely large-diameter holes, ensuring that the alignment error between the foam and the contacts after assembly is controlled within 0.1mm (far below the functional failure threshold of 0.3mm).

[0141] When a user presses the button, the stability of the conductive foam 320 directly determines the signal transmission quality. The tapered orifice solves the deformation limitation and tilt risk of traditional straight-tube orifices through gradient constraint: when pressed, the conductive foam 320 compresses inward, resulting in radial expansion (increased diameter). The large diameter inside the tapered orifice provides ample space for this expansion, avoiding pressing jams caused by friction between the foam and the inner side of the ribs (traditional straight-tube orifices, due to their fixed diameter, are prone to friction with the expanding foam, affecting the feel). At the same time, the large inner space allows for slight posture adjustments of the foam in the initial stage of compression, buffering the impact of uneven pressing pressure. The small diameter on the outer side of the tapered orifice (near the nameplate 400) fits tightly with the foam, firmly locking the position of the top of the foam—even if the force applied during pressing is uneven (such as leaning to one side), the top of the foam cannot tilt significantly, ensuring that its bottom always remains aligned with the PCB board contact. This design, with fine adjustment at the bottom and strong constraint at the top, avoids signal interruption and ensures consistent pressing feel (no significant deviation in pressing force and travel feedback).

[0142] The 320 conductive foam needs precise repositioning during the rebound process after being pressed. The tapered structure of the tapered hole provides progressive guidance for the rebound, solving the repositioning offset problem that may exist with straight cylinder holes.

[0143] Optionally, the inclination angle of the tapered hole is greater than 5° and less than or equal to 30°.

[0144] One of the core values ​​of tapered orifices is that they provide assembly tolerance through the difference between the larger inner diameter and the smaller outer diameter. The smaller the angle, the smaller the difference between the inner and outer diameters. This tiny difference cannot accommodate slight offsets (such as ±0.2mm positional deviation) during the assembly of conductive foam 320, which can cause the foam to get stuck in the hole or misalign with the PCB contacts. This can easily lead to jamming and machine stoppages during automated assembly, and repeated calibration is required during manual assembly, reducing efficiency by more than 60%. At small angles, the slope of the tapered orifice is gentle, resulting in weak radial guidance for the foam: when pressed, the radial expansion of the foam easily leads to full contact with the hole wall, generating significant friction; when rebounding, the gentle slope cannot effectively guide the foam back to its original position, easily causing reset offset, leading to poor contact of the contacts during subsequent pressing.

[0145] The greater the tilt angle, the smaller the effective wall thickness of the ribs. Taking a rib root thickness of 1mm and a height of 2mm as an example, the outer wall thickness of the rib is approximately 0.87mm at a 30° angle, only about 0.77mm at a 40° angle, and further decreases to 0.64mm at a 50° angle. Excessive wall thickness will cause the ribs to be unable to withstand the radial force transmitted by the foam when pressed (especially when the user presses hard, the instantaneous force can reach over 50N), easily leading to breakage of the outer ribs or deformation at the root, directly causing the foam to lose its restraint and the button function to fail. Steep slopes with large angles can cause cutting friction on conductive foam 320: During assembly, the foam edge needs to quickly transition from a large aperture to a small aperture, and the steep slope can easily scratch the conductive layer on the foam surface (leading to a decrease in conductivity); when pressed, the direction of foam compression and expansion is perpendicular to the steep slope, which can easily cause local stress concentration (the local compression rate of the foam exceeds 80%, far exceeding the safety threshold of 60%), leading to accelerated foam aging—the service life drops from 50,000 presses to less than 20,000 presses. The gradient barrier of the tapered orifice relies on the inverted slope structure of the small aperture on the outside and the large aperture on the inside to guide foreign objects to slide off, but if the angle is >30°, the slope is too steep, which will cause dust to accumulate in the large aperture area on the inside: after external dust enters the small aperture on the outside, it will slide directly into the large space on the inside due to the insufficient blocking force of the steep slope, and it is difficult to be discharged by gravity (instead, it will be stuck due to the steep slope), resulting in the PCB board contacts being covered by dust, increasing the risk of signal transmission interruption by 300%.

[0146] Limiting the tilt angle of the tapered hole to greater than 5° and less than or equal to 30° is the optimal solution between functional effectiveness, structural reliability, and scenario adaptability. This ensures that the guiding, constraining, and protective functions of the tapered hole are fully utilized, while avoiding functional failure caused by an excessively small angle and structural damage caused by an excessively large angle. This solution can cover the design requirements of most wired controller buttons.

[0147] Optionally, the wired controller also includes a temperature and humidity sensor 316. The front shell 100 includes a base plate 110 and multiple side plates 120, which enclose an installation space. Two adjacent side plates 120 are respectively provided with a first ventilation hole and a second ventilation hole. The rear shell 200 covers the installation space. The PCB board is disposed in the installation space. The front shell 100 is provided with a first stop rib 154 corresponding to the ventilation hole and the second ventilation hole, and the rear shell 200 is provided with a second stop rib 230 corresponding to the ventilation hole and the second ventilation hole. The first stop rib 154 and the second stop rib 230 define a detection space in the installation space. The temperature and humidity sensor 316 is connected to the PCB board and located in the detection space.

[0148] The housing 10 of the wired controller includes a front housing 100 and a rear housing 200. The front housing 100 includes a base plate 110 and a plurality of side plates 120. The base plate 110 and the plurality of side plates 120 enclose and define a mounting space. The rear housing 200 covers the mounting space. In use, the base plate 110 and the plurality of side plates 120 of the wired controller are exposed outside the housing.

[0149] The front housing 100 has two adjacent side plates 120 with a first ventilation hole and a second ventilation hole. Between the first ventilation hole and the second ventilation hole, a first stop rib 154 and a second stop rib 230 define a detection space inside the housing 10 that connects the first ventilation hole and the second ventilation hole. The detection space is in communication with the surrounding environment. The area outside the detection space in the installation space is isolated from the space where the wired controller is located.

[0150] The temperature and humidity sensor 316 of the wired controller is mounted on the PCB board and located in the detection space. Indoor air enters the detection space through the first ventilation hole, flows through the temperature and humidity sensor 316, and then flows out through the second ventilation hole.

[0151] Using the wired controller provided in this embodiment, the first ventilation hole and the second ventilation hole are located on two adjacent side plates 120. The detection space occupies a small space within the installation space, which is beneficial for optimizing the layout of components inside the wired controller. The airflow path is relatively smooth as it enters from the first ventilation hole and flows out from the second ventilation hole, which is beneficial for the wired controller to accurately measure the humidity information of the indoor environment. The temperature and humidity sensor 316 is located in one corner of the wired controller, which can reduce or avoid interference caused by the heating elements of the PCB board to the detection of the temperature and humidity sensor 316. The PCB board is located between the first stop rib 154 and the second stop rib 230, which is beneficial for the installation and fixation of the PCB.

[0152] Optionally, the first ventilation hole is opened on the lower side plate 120 among the plurality of side plates 120, and the second ventilation hole is opened on a side plate 120 adjacent to the lower side plate 120.

[0153] The first heat exchanger is located on the lower side panel 120, which conceals the air inlet and reduces or prevents dust and droplets from entering the detection space. The second vent is located on a vertically positioned side panel 120, also reducing or preventing dust and droplets from entering the detection space. The wired controller generates slight heat during operation. The height difference between the first and second vents reduces the density of indoor air entering the detection space, making it easier for the air to exit through the second vent. This design provides a smoother airflow path for the wired controller, facilitating accurate detection of indoor humidity.

[0154] Optionally, the number of second ventilation holes is greater than the number of first ventilation holes.

[0155] With both the first and second ventilation holes comprising multiple micropores of the same diameter, the second ventilation hole has a greater number of pores than the first. This allows air to be more easily expelled from the detection space. As air is expelled from the detection space, a pressure difference is created, drawing in indoor air through the lower first ventilation hole. This arrangement facilitates air circulation between the detection space and the environment where the wired controller is located, based on the difference in thermal density.

[0156] Optionally, the area of ​​the second ventilation hole is larger than the total area of ​​the first ventilation hole.

[0157] The total area of ​​the second ventilation hole is larger than that of the first ventilation hole, making it easier for air to escape from the detection space. This arrangement facilitates air circulation within the detection space and the environment of the wired controller based on the density difference between hot and cold temperatures.

[0158] Optionally, the first stop rib 154 is arc-shaped.

[0159] The first stop rib 154 is arc-shaped, which guides airflow from the first ventilation hole to the second ventilation hole. The arc shape of the first stop rib 154 reduces the dead angle of airflow in the detection space, thereby improving the detection accuracy of the temperature and humidity sensor 316.

[0160] Optionally, the second stop rib 230 is arc-shaped.

[0161] The second stop rib 230 is arc-shaped, which guides airflow from the first ventilation hole to the second ventilation hole. The arc shape of the second stop rib 230 reduces the dead angle of airflow in the detection space, thereby improving the detection accuracy of the temperature and humidity sensor 316.

[0162] Optionally, the first stop rib 154 extends to the PCB board.

[0163] In use, one side of the PCB board abuts against the first stop rib 154. This not only improves airflow between the detection space and other parts of the installation space, but also allows the wired controller to be fixed by the first stop rib 154, which is beneficial for the installation and fixation of the wired controller.

[0164] Optionally, the second stop rib 230 extends to the PCB board.

[0165] Under the yellow platform, the other side of the PCB board abuts against the second stop rib 230, and the PCB board is clamped between the first stop rib 154 and the second stop rib 230. This not only isolates the area outside the detection space from the detection space in the installation space, but also allows the first stop rib 154 and the second stop rib 230 to jointly fix the PCB board.

[0166] Optionally, the diameter of the first vent gradually decreases from the outside to the inside.

[0167] The diameter of the ventilation holes gradually decreases from the outside to the inside, which increases the airflow velocity and guides the airflow direction when outside air enters the detection space. Furthermore, this design can reduce or prevent external water from entering the detection space.

[0168] Optionally, the front housing 100 is constructed with a first screw post 153, and the first screw post 153 and the first stop rib 154 are integrally formed.

[0169] Traditional PCB fixing methods using screw posts exert significant localized pressure on the PCB, potentially leading to PCB deformation or internal circuit malfunctions. The integrated design of the first screw post 153 and the first stop rib 154 increases the contact area between the fixing components and the PCB when fixing it with screws, reducing or preventing PCB deformation or circuit malfunctions.

[0170] Optionally, the rear shell 200 is constructed with a second screw post 220, which is an integral structure with the second stop rib 230.

[0171] The second screw post 220 and the second stop rib 230 of the rear shell 200 are integrated into one structure, which increases the contact area between the fixing component and the PCB board and reduces or avoids PCB board deformation or circuit failure.

[0172] Optionally, the area of ​​the PCB board located in the detection space is constructed with a notch, and the temperature and humidity sensor 316 is located within the notch.

[0173] The PCB board has a notch, a notched corner design. This allows the temperature and humidity sensor 316 to be positioned independently of the PCB board, reducing size limitations. Furthermore, the notched corner design creates a relatively open and complete detection space, facilitating air circulation between the humidity monitoring area and the indoor environment, thus improving the accuracy of indoor humidity detection.

[0174] Optionally, the temperature and humidity sensor 316 is connected to the outward side of the PCB board and extends into the detection space, with the temperature sensing bulb of the temperature and humidity sensor 316 facing the ventilation hole.

[0175] The temperature and humidity sensor 316 is connected to the outward-facing side of the PCB board via pins, facilitating the soldering of different components onto the PCB board. The temperature and humidity sensor 316 extends into the detection space, generally along the length and width of the PCB board, thus minimizing the overall thickness of the PCB board and preventing significant increases in thickness due to the sensor. The sensing bulb of the temperature and humidity sensor 316 faces the ventilation vent, allowing for ample contact with the air entering the detection space, thereby more accurately detecting indoor humidity information.

[0176] Optionally, the diameter of the first ventilation hole 151 gradually decreases from the outside to the inside, and the downward side of the first ventilation hole 151 slopes downward from the inside to the outside.

[0177] The first ventilation hole 151 is a critical channel for the sensor to contact the external environment, requiring a balance between detection efficiency and protection performance. The diameter of the first ventilation hole 151 gradually decreases from the outside to the inside. The larger outer diameter ensures sufficient airflow, allowing the sensor to respond quickly to changes in ambient humidity; the smaller inner diameter reduces the direct intrusion of dust and moisture into the sensor, extending its lifespan. The downward-facing side of the detection hole slopes downwards from the inside to the outside, forming a guide slope. If a small amount of condensation or dust falls on the hole wall, it can naturally slide outwards through the slope, preventing it from accumulating inside the hole and seeping into the installation space, damaging the PCB board or the sensor. The gap between the side of the rear shell 200 and the side plate 120 of the front shell 100 is less than 0.05mm. When the front shell 100 and the rear shell 200 are closed, jamming may occur due to processing errors, or structural deformation may occur due to thermal expansion and contraction after long-term use, affecting disassembly and maintenance. If the gap is greater than 0.1mm, it will compromise the airtightness of the installation space, allowing external dust and moisture to easily enter the interior, leading to short circuits or decreased sensor detection accuracy. A gap of 0.05-0.1mm ensures structural stability after the cover is closed, while also allowing for slight assembly error tolerance and maintaining basic dust and moisture protection capabilities.

[0178] The wired controller provided in this embodiment, through the gradual aperture and inclined design of the first ventilation hole 151, ensures effective contact between the sensor and air, reduces interference from external impurities, and improves the accuracy and long-term stability of the detection data. The narrow gap design between the front shell 100 and the rear shell 200, combined with the inclined airflow guiding design of the detection hole, forms double protection, effectively blocking dust and moisture intrusion, extending the service life of the PCB board and the sensor, and reducing the failure rate. The gap between the front shell 100 and the rear shell 200 avoids the problem of excessively tight or loose assembly, ensuring product assembly efficiency and ensuring that the structure does not loosen or deform during long-term use, thus improving the overall durability of the product.

[0179] Optionally, the upward-facing side of the first vent 151 is inclined upward from the inside out.

[0180] At this point, the detection hole forms an outward-expanding flared structure, with its cross-section showing an outward-opening shape on both sides. The flared structure formed by the bidirectional tilt increases the area for external air to enter, while the smooth transition of the internal channel reduces airflow resistance, making it easier for ambient air to enter and contact the temperature and humidity sensor 316, thus improving the detection response speed. The downward-sloping surface continues to guide airflow, expelling any condensate or liquid that may enter, while the upward-sloping surface prevents dust accumulation on the upper wall of the hole, reducing dust settling due to gravity and lowering cleaning and maintenance requirements. The bidirectional tilt design creates a rib-like structure at the edge of the detection hole, reducing stress concentration at the opening on the front shell 100 side plate 120 and improving overall structural stability. Through the combination of the upward-sloping design and the original downward-sloping structure, the wired controller maintains detection accuracy while further improving its adaptability and service life in complex environments.

[0181] Optionally, the cross-section of the first ventilation hole 151 is elliptical.

[0182] Under the premise of the same opening area as a circular cross section, an elliptical cross section can expand the effective width of air contact by extending along its major axis. In particular, when the major axis of the ellipse is aligned with the airflow direction, it can reduce the resistance of air entering the hole, allowing external ambient air to reach the temperature and humidity sensor 316 more quickly and evenly, further improving the detection response speed.

[0183] Most temperature and humidity sensors (316) have a rectangular or elliptical (not strictly circular) sensing area. The elliptical sensing aperture better matches the sensor's sensing range, avoiding the problem of insufficient contact between the sensor's edge areas and air caused by partial obstruction in circular apertures, thus improving the uniformity of the detection data. The minor axis of the elliptical cross-section allows for more precise control of the channel height within the aperture. The minor axis dimension can be slightly larger than the thickness of the sensor's sensing end, ensuring stable sensor alignment with the aperture while reducing ineffective space within the aperture, lowering the probability of dust accumulation and condensation retention. Simultaneously, the smooth, curved surface of the ellipse eliminates sharp corners, allowing dust and moisture to slide off more easily, preventing accumulation in the corners of the aperture.

[0184] The front housing 100 and side plate 120 are thin-walled structures. Circular holes are prone to localized stress concentration at their edges, especially under long-term thermal cycling, increasing the risk of cracking. The elliptical cross-section, with its smoother transition, disperses stress to the curved areas at both ends of the major axis, reducing the impact of the holes on the structural strength of the front housing 100 and side plate 120, and improving the overall durability of the wired controller. In actual production assembly, the temperature and humidity sensor 316 needs to precisely align with the detection hole. The major axis of the elliptical cross-section provides a certain degree of assembly tolerance: even with a slight installation offset in the major axis direction, the sensor's sensing area can still be covered by the major axis of the elliptical hole, avoiding sensor misalignment and detection failure due to installation errors. This reduces the precision requirements of production assembly and improves the yield rate.

[0185] Optionally, one of the side plates 120 located at the bottom is provided with a second ventilation hole 152. The front shell 100 is provided with a first stop rib 154 corresponding to the second ventilation hole 152 and the first ventilation hole 151. The rear shell 200 is provided with a second stop rib 230 corresponding to the first stop rib 154. The first stop rib 154 and the second stop rib 230 define a detection space in the installation space. The temperature and humidity sensor 316 is located in the detection space.

[0186] The second ventilation hole 152 is located on the lower side plate 120 among the multiple side plates 120, forming an airflow channel with the upper first ventilation hole 151 as the entrance for external air into the installation space. The first stop rib 154 is integrally formed on the inner side of the front shell 100, and is set corresponding to the edges of the second ventilation hole 152 and the first ventilation hole 151 (e.g., extending along the upper edge of the second ventilation hole 152 and the lower edge of the first ventilation hole 151), forming a strip-shaped protruding structure. The first stop rib 154 cooperates with the second stop rib 230 of the rear shell 200 to form the front boundary of the detection space, preventing external dust and moisture from directly diffusing from the second ventilation hole 152 / first ventilation hole 151 to other areas of the installation space.

[0187] The second stop rib 230 and the first stop rib 154 together form the closed boundary of the detection space, creating an independent small space. This further enhances the sealing effect and prevents air in the detection space from flowing into other areas of the installation space. The detection space is an independent small space enclosed by the first stop rib 154, the second stop rib 230, the inner wall of the front shell 100 (corresponding to the area of ​​the second ventilation hole 152 / first ventilation hole 151), and the inner wall of the rear shell 200. Its volume only accommodates the temperature and humidity sensor 316 and a small area of ​​PCB board. This area provides a dedicated detection environment for the temperature and humidity sensor 316, reduces external interference, and ensures that the sensor only comes into contact with filtered air.

[0188] The installation space of the wired controller is divided into two main areas: detection space: the core functional area, which only houses the temperature and humidity sensor 316. It is equipped with an independent airflow loop through the second ventilation hole 152 and the first ventilation hole 151. Non-detection space: which houses the main circuit of the PCB board and other electronic components (such as buttons, display drive circuits, etc.). It is isolated from the detection space by ribs to prevent moisture and dust in the detection space from affecting the core circuit.

[0189] The second ventilation port 152 and the first ventilation port 151 form an upward and downward convection airflow path. Compared with a single detection port, the advantages of this design are: more stable airflow: external air flows in naturally from the second ventilation port 152 below (using the convection principle of hot air rising and cold air sinking), and after fully contacting the temperature and humidity sensor 316 in the detection space, it is discharged from the first ventilation port 151 on the side / top, forming active convection, avoiding detection lag caused by air stagnation in the detection space (such as the sensor having to wait for air replacement in the port after the ambient humidity changes before it can identify); controllable air intake: the second ventilation port 152 below can be adjusted in diameter (such as slightly larger than the first ventilation port 151) to ensure sufficient air and a slow flow rate in the detection space, which ensures that the sensor can quickly capture humidity changes, while avoiding condensation on the sensor surface due to excessively fast airflow (especially in high humidity environments).

[0190] The coordinated design of the first and second stop ribs 230 is the core of achieving independence and protection for the detection space. The closed boundary formed by the ribs completely separates the detection space from the non-detection space, effectively blocking the spread of contaminants and temperature interference. Specifically, the main circuit of the PCB board generates heat when it is working (such as chip heating). If it comes into direct contact with the temperature and humidity sensor 316, it will cause the temperature of the air around the sensor to rise, thereby affecting the accuracy of humidity detection (humidity detection is sensitive to temperature). If a small amount of dust or moisture is brought into the detection space due to air intake, the ribs can prevent it from spreading to the core circuit of the non-detection space, reducing the risk of short circuits.

[0191] Optionally, the cross-section of the second ventilation hole 152 gradually decreases from the outside to the inside.

[0192] Based on the second ventilation hole 152 opened in the lower side plate 120, the cross section of the second ventilation hole 152 is further designed to gradually decrease from the outside to the inside (i.e., a gradual structure with a wider outer width and a narrower inner width). This can form a deep synergy with the original design such as the detection space and the stop ribs, and achieve performance upgrades in three aspects: air guidance, impurity filtration, and protective sealing.

[0193] The outer width and inner narrowing gradient structure of the second ventilation hole 152 optimizes airflow guidance and improves the air replacement efficiency of the detection space. The larger outer cross-sectional size of the second ventilation hole 152 can increase the contact area with the outside air. Especially in natural convection scenarios, it can capture airflow more efficiently, ensuring that enough air enters the hole and providing a stable air source for the detection space. This avoids air stagnation in the detection space due to insufficient air intake and solves the problem of insufficient contact between the sensor and fresh air, resulting in detection lag.

[0194] The cross-sectional size of the inner side of the second ventilation port 152 (facing the detection space) is reduced. According to fluid dynamics principles, the airflow will accelerate due to the cross-sectional contraction when passing through the gradient channel, forming a more stable directional airflow (rather than a diffused airflow). The accelerated airflow can quickly enter the detection space and achieve rapid contact and full displacement with the temperature and humidity sensor 316, further shortening the sensor's response time to changes in ambient humidity, making it particularly suitable for humidity control scenarios sensitive to humidity changes. The gradient structure, wider on the outside and narrower on the inside, naturally possesses a physical filtration function, effectively blocking external impurities from entering.

[0195] Optionally, the wired controller includes a mounting box 500 and a wired controller body. The mounting box 500 includes a back plate 510 and a plurality of side plates 520 connected to the back plate 510. The plurality of side plates 520 and the back plate 510 enclose and define an embedding space. The side plates 520 extend along the length and width directions of the back plate 510 and are provided with a retaining edge 540. The wired controller body includes a front shell 100 and a rear shell 200. The front shell 100 is configured with an installation space. The rear shell 200 covers the installation space. The middle part of the rear shell 200 protrudes rearward. The protruding part of the rear shell 200 is embedded in the embedding space, and the retaining edge 540 is embedded in the non-protruding part of the edge of the rear shell 200. The rear shell 200 and the mounting box 500 are engaged by a snap fastener.

[0196] The wired controller provided in this embodiment includes a mounting box 500 and a controller body. When installing the wired controller, the mounting box 500 is first fixed into a pre-embedded box, such as an 86-type switch box. Then, the wired controller body is wired. After wiring is completed, the controller body is embedded into the mounting box 500, thereby fixing the controller body in place.

[0197] The mounting box for the wired controller includes a back plate 510 and multiple side plates 520. The back plate 510 and the multiple side plates 520 are connected to form a recessed embedding space. The embedding space is used to accommodate the protruding part of the wired controller body. The mounting box 500 also includes a retaining edge 540 extending outward from the side plates 520, with the retaining edge 540 extending along the length and width directions of the back plate 510. When fixing the mounting box 500, the retaining edge 540 abuts against the outer periphery of the pre-embedded box. This facilitates control over the depth to which the mounting box 500 extends into the pre-embedded box, which is beneficial for the installation and positioning of the wired controller body. Specifically, even if the depths of the pre-embedded boxes are different, because the retaining edge 540 can abut against the outer periphery of the pre-embedded box, the mounting box 500 can have the same embedding depth in pre-embedded boxes of different depths.

[0198] When installing the wired controller body, the retaining edge 540 abuts against the inward-facing side of the wired controller body. Specifically, the middle portion of the wired controller body protrudes rearward, while the edge portion does not protrude. The protruding portion of the wired controller body is located in the embedding space, and the retaining edge 540 abuts against the non-protruding portion of the wired controller body. In this way, the retaining edge 540 can be used to complete the installation and positioning of the wired controller body.

[0199] Using the wired controller provided in this embodiment, the separate installation of the mounting box 500 and the wired controller body allows for accurate installation of the wired controller body in various types of pre-embedded boxes. When fixing the mounting box 500, it is not necessary to connect a wiring harness to the wired controller body; the mounting box 500 can be easily fixed to the pre-embedded box. The snap-fit ​​connection between the wired controller body and the mounting box 500 makes assembly and disassembly easy, facilitating user operation. The recess 540 of the mounting box 500 is embedded in the rear shell 200 of the wired controller, reducing the thickness of the wired controller after installation and improving its aesthetics.

[0200] Optionally, both opposite flanges 540 are constructed with a downwardly recessed platform 541, the platform 541 having bolt holes through which the rear shell 200 is fixed to the bottom box.

[0201] The plane of the countersunk plate 541 is lower than the plane of the retaining edge 540. After the bolt is screwed in, the bolt head is above the countersunk plate 541 and below the plane of the retaining edge 540. This ensures that the bolt will not interfere with the locking mechanism of the control box body when it is screwed in. Furthermore, the downwardly recessed countersunk plate 541 reduces the distance between the bolt hole and the bolt fastener inside the box, making it easier for the bolt tail to align with the bolt fastener after the bolt is inserted into the bolt hole of the countersunk plate 541.

[0202] Optionally, the flange 540 is inclined from the inside out from front to back.

[0203] "Inside and outside" refers to the mounting box 500 itself, and is the direction from the center of the installation outwards on the plane of the retaining edge 540. "Front and back" also refers to the mounting box 500 itself, and is the direction from the front inwards along the depth of the embedded box.

[0204] When fixing the mounting box 500, it is secured to the embedded box using bolts. As the bolts are tightened, the mounting box 500 is pulled from the outside in. Because the retaining flange 540 is angled, it acts like a spring. As the bolts are screwed in, the retaining flange 540 gradually becomes parallel to the wall surface where the mounting box 500 is located. In this state, the retaining flange 540 generates a spring force that pulls the mounting box 500 outward, thereby tightening the bolts. This design ensures a more secure fixation between the mounting box 500 and the embedded box, preventing the bolts from easily loosening.

[0205] Optionally, the rear cover 200 is configured with a receiving groove 201, the depth of which is greater than or equal to the thickness of the retaining edge 540, which is embedded in the receiving groove 201.

[0206] The receiving groove 201 of the rear shell 200 is used to accommodate the retaining edge 540 of the mounting box 500. Since the depth of the receiving groove 201 is greater than the thickness of the retaining edge 540, the retaining edge 540 can be completely accommodated in the receiving groove 201. In this way, although the retaining edge 540 protrudes from the wall after the mounting box 500 is fixed, the receiving groove 201 of the rear shell 200 of the wire controller body can cover the retaining edge 540 within the wire controller body, avoiding gaps between the wire controller body and the wall after installation, and improving the aesthetics of the wire controller in use.

[0207] Optionally, the back plate 510 of the mounting box 500 extends along the four sides and is provided with four flanges 540, and the rear shell 200 is constructed with four receiving grooves 201, with a thicker reinforcing part 240 formed between two adjacent receiving grooves 201.

[0208] The back plate 510 of the mounting box 500 extends and is provided with four retaining edges 540, which can abut against the four outer peripheries of the embedded box. Correspondingly, the rear shell 200 is constructed with four receiving grooves 201 to accommodate the four retaining edges 540 within the four receiving grooves 201. A thicker reinforcing portion 240 is formed between two adjacent receiving grooves 201, which can improve the structural strength of the rear shell 200 at the four corners and reduce or avoid damage to the internal electronic control components caused by twisting the remote control.

[0209] Optionally, the front shell 100 includes a base plate 110 and a plurality of side plates 120, the base plate 110 and the plurality of side plates 120 enclosing and defining an installation space, and the side plates 120 of the front shell 100 shielding the rear shell 200.

[0210] The front cover 100, consisting of a substrate 110 and multiple side plates 120, encloses a mounting space capable of accommodating components such as PCB boards. The fitted side plates 120 conceal the rear cover 200, as well as its receiving groove 201 and the retaining edge 540 located within the receiving groove 201. Once the wired controller is installed, from the user's perspective, only the substrates 110 and the side plates 120 are visible; the rear cover 200 and the mounting box 500 are not.

[0211] This setup not only improves the aesthetics of the wired controller but also reduces or prevents water vapor and dust from entering the installation space.

[0212] Optionally, one of the multiple flanges 540 extends to provide a disassembly mating part 542, the disassembly mating part 542 and the rear shell 200 form a disassembly opening 105, the side plate 120 is provided with a disassembly clearance opening 530 corresponding to the disassembly opening 105, and the disassembly mating part 542 extends into the disassembly clearance opening 530.

[0213] When removing the wired controller body, the pry bar is inserted into the disassembly port 105 through the disassembly clearance port 530. When the pry bar is rotated, a force can be applied to separate the disassembly mating part 542 and the wired controller body, thereby releasing the jamming between the wired controller body and the mounting box 500.

[0214] This configuration allows the wired controller to be easily removed from the mounting box 500.

[0215] Optionally, the rear shell 200 is partially thinned to form a disassembly groove, with the disassembly mating part 542 corresponding to the groove.

[0216] When the rear shell 200 forms the receiving groove 201, a disassembly opening 105 is formed between the disassembly mating part 542 and the bottom of the receiving groove 201. The partial thinning design of the rear shell 200 allows the disassembly mating part 542 to be set to the same thickness as the retaining edge 540, which is beneficial to the processing and forming of the mounting box 500.

[0217] Optionally, the rear shell 200 has an inclined guide surface in part of the structure corresponding to the disassembly mating part 542.

[0218] With the rear cover 200 having an inclined guide surface, tools such as pry bars can more easily be inserted into the disassembly port 105.

[0219] Optionally, the disassembly mating part 542 is constructed with a disassembly chamfer.

[0220] The disassembly mating part 542 is equipped with a disassembly chamfer, which can be compatible with different disassembly tools and further facilitates user operation.

[0221] Optionally, one side wall of the rearward protrusion of the rear shell 200 is provided with a first buckle 251, and one inner wall of the mounting box 500 embedded in the space is provided with a first engaging part 551 corresponding to the first buckle 251; the other side wall of the rearward protrusion of the rear shell 200 is provided with a second buckle 252, and the other side wall of the mounting box 500 embedded in the space is provided with a second engaging part 552 corresponding to the second buckle 252; wherein, the first buckle 251 and the second buckle 252 are opposite to each other, and the first engaging part 551 and the second engaging part 552 are opposite to each other.

[0222] The first latch 251 and the second latch 252 are located in opposite positions, and the first engaging part 551 and the second engaging part are located on two opposite side walls of the embedding space. This improves the engagement effect of the mounting box 500 with the electrical control box body.

[0223] Optionally, the rear shell 200 is provided with a positioning part 210, and the mounting box 500 is provided with a positioning mating part 553, wherein the positioning part 210 and the positioning mating part 553 are offset from the center line of the rear shell 200 in the lateral or longitudinal direction.

[0224] The design of the positioning part 210 and the positioning mating part 553 serves as a foolproof method when installing the electrical control box, preventing installers from installing the electrical controller upside down.

[0225] Optionally, a vertical drainage channel 502 is formed between the mounting box 500 and the rear shell 200.

[0226] Small amounts of liquid seeping in from the outside (such as bathroom steam condensate or kitchen grease) enter the interior through the tiny gap between the mounting box 500 and the rear shell 200 (such as the fit gap between the flange 540 and the groove). Due to gravity, the liquid flows downwards and collects at the bottom of the mounting box 500. The arc-shaped transition surface of the raised part of the rear shell 200 guides the accumulated water to flow towards the drainage opening of the enclosure 520. At the same time, the guide channel that accommodates the groove 201 directs the water in the groove into the bottom channel. The collected water enters the drainage opening through the reserved gap between the rear shell 200 and the bottom of the enclosure 520, and is finally discharged vertically to the outside of the mounting box 500.

[0227] In scenarios such as bathrooms and kitchens where there is frequent contact with moisture, condensation can easily form in the gap between the mounting box 500 and the back cover 200. The drainage channel 502 can drain the condensed water droplets in real time, preventing the growth of mold caused by long-term accumulation (mold may corrode the housing 10 or the wiring) and extending the service life of the wired controller.

[0228] Optionally, the edge of the retaining flange 540 is thinned to form a drainage channel 502 between it and the sidewall of the receiving groove 201.

[0229] The mounting box 500 and the two sides of the retaining edge 540 (the longitudinal edges along the length direction) are thinned to form a stepped or sloping structure that is thicker in the middle and thinner at the edges (the width of the thinned area is 1-2 mm, and the thickness is reduced by 0.1-0.2 mm compared to the middle area); a small gap (0.1-0.2 mm) is formed between the thinned edge and the side wall of the receiving groove 201, which is the core flow channel of the drainage channel 502; the thick area in the middle is still tightly fitted to the side wall of the groove to ensure horizontal positioning and sealing.

[0230] Condensation and small amounts of liquid (such as bathroom moisture and kitchen grease) seeping in from the outside enter the receiving groove 201 through the tiny gap between the baffle 540 and the groove. Due to gravity, they gather at the bottom of the groove. The collected water comes into contact with the gap (drainage channel 502) formed by the thinned edge of the baffle 540 and the side wall of the groove, and flows downward naturally along the gap. The water continues to flow downward along the channel, passes through the mating area between the protruding part of the rear shell 200 and the surrounding plate 520 of the mounting box 500, and is finally discharged from the bottom of the mounting box 500 (or the preset drainage gap).

[0231] The design of thinning the edge of the retaining flange 540 to form a drainage channel 502 between it and the side wall of the receiving groove 201 is a refined integration and optimization of the external protection system of the wired controller. By adjusting the shape of the retaining flange 540 itself, the drainage function and structure are integrated without sacrificing positioning accuracy and sealing performance. This simplifies the process, reduces costs, and further improves the reliability of the wired controller in humid environments, making it particularly suitable for applications with compact structures and high protection requirements.

[0232] Optionally, the front side of the housing 10 is divided into two areas, left and right, one area having a display window 101 and the other area serving as a touch area 12; a PCB board is disposed in the mounting space, the PCB board including a first area and a second area, the first area corresponding to the display window 101, and the second area having contacts; a display module 310 is connected to the first area of ​​the PCB corresponding to the display window 101; conductive foam 320 is disposed in the mounting space corresponding to the contacts; a nameplate 400 is disposed on the front side of the housing 10, the nameplate 400 shielding the display window 101 and the touch area 12.

[0233] As a control component of an air conditioner, the wired controller sends control signals to the air conditioner via wired or wireless means and receives operating status information from the air conditioner.

[0234] When the wired controller uses wireless control, it is equipped with batteries or connected to high-voltage power. High-voltage power is the opposite of low-voltage power used for control signals, and it is generally AC mains power. When the wired controller uses wired control, it is connected to the air conditioner via a wiring harness. The wiring harness includes signal wires for transmitting and receiving control signals. In some cases, the wiring harness may also include power wires for providing power input to the wired controller. If the wiring harness includes power wires, the wired controller does not need to be connected to high-voltage power.

[0235] In this embodiment, the housing 10 of the wired controller forms an installation space inside, which is used to install components such as PCB board and power board 330.

[0236] The outer side of the housing 10 of the wired controller is the main viewing surface of the controller. The outer side of the housing 10 is divided into two areas, left and right, one area having a display window 101 and the other area serving as a touch area 12. For example, the display window 101 is located on the left side of the housing 10, and the touch area 12 is located on the right side.

[0237] The PCB board of the wired controller has a first area and a second area on its outward-facing side. The first area corresponds to the display window 101, and the second area corresponds to the touch area 12. The first area of ​​the PCB board is used to connect to the display module 310, and the second area is provided with contacts to realize the button control of the wired controller. More specifically, the PCB board is also divided into left and right areas. The left area is used to connect to the display module 310, and the right area is provided with contacts.

[0238] The conductive foam 320 is connected to the contact. When the conductive foam 320 is pressed from the outside in, the conductive foam 320 becomes conductive, and the corresponding contact becomes conductive, thereby sending a corresponding control signal.

[0239] The computer board has multiple raised components, which are located in the same area as the contacts.

[0240] The nameplate 400 serves as the outer appearance of the wired controller, obscuring the touch area 12 of the display window 101. When the wired controller is not in operation, the outer appearance of the wired controller is uniform. When the wired controller is in operation, the display area 11 displays information, and the nameplate 400 is equipped with button prompts for corresponding button operations.

[0241] The wired controller provided in this embodiment features a left-right partitioned design on its outward-facing side, allowing for separation of display and touch functions. For the display module 310, since an integrated touch layer is unnecessary, the thickness and cost of the display module 310 are reduced. The direct connection of the display module 310 to the PCB board further reduces the overall thickness of the PCB board and display module 310. Combined with the button design of the conductive foam 320, the thickness of the wired controller is also reduced. The touch area 12 and display area 11 are completely independent, eliminating the need for users to switch between viewing the display and finding buttons. Furthermore, the physical buttons can be guided by button prompts for precise operation, significantly reducing the accidental touch rate. Simultaneously, during single-handed operation, the hand only needs to operate on one side of the touch area 12, without needing to cross the display area, which is ergonomic and improves interaction efficiency.

[0242] Optionally, the display module 310 includes a backlight module 311 and a display module 312, wherein the backlight module is connected to a first area of ​​the PCB board; and the display module 312 is connected to the first area of ​​the PCB board and is located outside the backlight module 311.

[0243] The display module 310 is divided into a backlight module 311 and a display module 312, both of which are directly integrated into the first area of ​​the PCB board. Both the backlight module 311 and the display module are directly connected to the first area of ​​the PCB board, establishing physical and electrical connections. The pins of the backlight module are fixed to a dedicated interface in the first area of ​​the PCB board via soldering or plug-in connections, while the display module 312 is directly attached to the first area of ​​the PCB board via board-to-board connection or pin soldering, without the need for additional adapter boards or cables. The backlight module 311 is positioned closer to the PCB board, serving as the light source supply layer; the display module 312 is located outside the backlight module 311, serving as the signal display layer. The backlight module 311 provides a uniform and adjustable light source, ensuring clear display of content under different lighting conditions such as low light and strong light; the display module 312 receives the air conditioner operation signal transmitted from the PCB board, converts the electrical signal into a visual image or text, and transmits it to the user through the display window 101.

[0244] Compared to the integrated display module 310, the split design eliminates the need for an integrated packaging shell, and the two modules are directly bonded together without redundant gaps. Both modules are directly connected to the PCB board, eliminating the need for ribbon cables / adapters and avoiding any increase in the thickness of the display module 310 due to packaging or adapter components. This perfectly aligns with the overall goal of a thinner wired controller. The backlight module 311 and display module 312 can be selected independently based on the different needs of the air conditioner wired controller. For example, for an economical wired controller, a low-power monochrome backlight module 311 + segment display module 312 can be selected; for a high-end wired controller, a multi-brightness adjustable backlight module 311 + dot matrix display module 312 can be selected, without needing to replace the entire display module 310, thus reducing customization costs.

[0245] The backlight module is bonded to the PCB board, which further reduces the overall thickness of the display module 310. Exemplarily, one side of the backlight module 311 is bonded to the PCB board, and the pins of the backlight module 311 extend from the periphery or upward side to the PCB board. The display module 312 is located outside the backlight module 311; exemplaryly, the display module 312 is bonded to the outward-facing side of the backlight module 311, which further reduces the overall thickness of the display module 310.

[0246] Optionally, an indicator light 315 is provided on one side end face of the display module 312, and a display notch 102 is provided on the display window 101 corresponding to the indicator light 315.

[0247] The indicator light 315 on the side of the display module 312 indicates the start / stop status of the air conditioner. Since the indicator light 315 is located on the side of the display module 312, no additional lighting is needed; the information is displayed using the backlight module 311, reducing the cost of the wired controller. The display window 101 has a display notch 102 corresponding to the indicator light 315, and the indicator light 315 is located on the side of the display module 312. The indicator light 315 does not affect the content displayed on the display module 310, and the asymmetrical arrangement makes the overall appearance of the wired controller more aesthetically pleasing.

[0248] Optionally, the display module 312 also includes a driver board 313 and a display panel 314, wherein the driver board 313 is connected to the PCB board through multiple pins; the display panel 314 is located outside the driver board 313 and is embedded in the display window 101.

[0249] The display panel 314 of the display module 312 is embedded within the display window 101. This embedded design reduces the overall thickness of the housing 10. The driver board 313 is connected to the PCB board via multiple pins, enabling signal transmission and fixing of the driver board 313, thus securing the entire display module 310. Traditional display panels 314 often use a design where the driver board 313 and the entire panel are attached to the outside of the display window 101, requiring the housing 10 to reserve space for the thickness of the driver board 313, the panel thickness, and assembly clearance. In this design, the display panel 314 is embedded within the display window 101, and the driver board 313 is suspended above the PCB board via pins. This eliminates the need for additional redundant space in the front-to-back direction of the housing 10, directly compressing the thickness of the housing 10 to match the target depth of the thinner wired controller.

[0250] Optionally, the area of ​​the drive board 313 is larger than the area of ​​the display panel 314, and a step is formed between the drive board 313 and the display panel 314. The step abuts against the inward periphery of the display window 101 through a seal.

[0251] The area of ​​the driver board 313 in the horizontal direction (parallel to the PCB board surface) is larger than that of the display panel 314. Specifically, the upper and lower edges or left and right edges of the driver board 313 extend beyond the corresponding edges of the display panel 314, forming an annular step around the perimeter of the display panel 314. The height difference of the step is consistent with the thickness difference between the driver board 313 and the display panel 314—that is, the difference between the thickness of the driver board 313 and the thickness of the display panel 314 constitutes the vertical height of the step, ensuring that after the two are fitted together, a flat step structure with clear boundaries is formed, without misalignment or gaps. The sealing element is made of elastic material (such as silicone sealing strips or sponge sealing gaskets) and is arranged in an annular structure around the end face of the step formed by the driver board 313 and the display panel 314 (that is, the side of the driver board 313 that extends beyond the display panel 314 and faces the display window 101). When the display panel 314 is embedded in the display window 101, the seal is tightly abutted against the inward periphery of the display window 101 (i.e., the inner edge of the display window 101 of the housing 10), forming a closed-loop contact structure of the periphery of the display window 101, the seal, and the step end face. The seal undergoes slight elastic deformation under pressure, ensuring the sealing of the contact. The driver board 313 is still vertically connected to the first area of ​​the PCB board through multiple pins to achieve signal transmission and initial fixation of the driver board 313. The display panel 314 is embedded in the display window 101, and its outer surface is flush with or slightly convex to the front side of the housing 10. The step of the driver board 313 abuts against the periphery of the display window 101 through the seal, forming a dual positioning of pin fixing and step abutment, further restricting the displacement of the display module 312.

[0252] The tight contact between the annular seal and the periphery of the display window 101 effectively prevents external dust and moisture from entering the internal installation space of the housing 10 through the gap between the display window 101 and the display panel 314. This avoids problems such as short circuits and performance degradation in components like the PCB board and backlight module 311 due to dust accumulation or moisture. It is especially suitable for installation scenarios that are damp and dusty, such as kitchens and bathrooms, and extends the service life of the wired controller. The area of ​​the drive board 313 is larger than the step formed by the display panel 314. Combined with the contact effect of the seal, it is equivalent to adding a circumferential support point to the display module 312. Compared with a structure that is only fixed by pins, this design can disperse the external forces (such as pressing and vibration) on the display module 312, preventing the pins from bending or falling off due to excessive force at a single point. At the same time, it prevents the display panel 314 from shaking within the display window 101, thus improving structural stability. The step directly abuts against the periphery of the display window 101 via a seal, eliminating the need for an additional support frame or fixing clips and preventing any increase in the wired controller's thickness. Furthermore, the seal's thin design allows for tight filling of gaps after elastic deformation, achieving both sealing and fixation while perfectly aligning with the overall slim design goal of the wired controller. During assembly, simply embed the display panel 314 into the display window 101, allowing the seal at the step to naturally abut against the window's periphery, to complete the positioning of the display module 312; no additional adjustments or adhesive fasteners are required. Simultaneously, the larger area of ​​the drive board 313 provides more operating space during pin soldering, reducing soldering errors and improving production efficiency.

[0253] Optionally, the touch area 12 of the housing 10 has a button hole 103, and the conductive foam 320 passes through the button hole 103 and is located between the PCB board and the nameplate 400.

[0254] The conductive foam 320 passes directly through the button hole 103 and corresponds to the contact point on the PCB board. When the user presses the nameplate 400 corresponding to the touch area 12, the pressure is directly transmitted to the conductive foam 320, allowing the conductive foam 320 to quickly conduct to the contact point on the PCB board, improving the button response sensitivity. The button hole 103 physically limits the conductive foam 320, preventing it from shifting during pressing and ensuring that each press accurately corresponds to the preset contact point, reducing the risk of accidental touches or operational failures. After passing through the button hole 103, the conductive foam 320 is directly clamped between the PCB board and the nameplate 400, eliminating the need for additional button brackets or protruding structures to support the touch components, simplifying the structural hierarchy of the touch area 12. Compared to the traditional button design that requires additional installation space, this compact stacking form can further reduce the thickness of the touch area 12, thereby reducing the overall thickness of the wired controller and meeting the requirements of a thin and light design. The button hole 103 serves to fix the conductive foam 320, preventing it from detaching from the contact point due to vibration or deformation during transportation or long-term use, thus enhancing the structural stability of the touch component. After passing through the button hole 103, the conductive foam 320 adheres to the inside of the nameplate 400, which can fill the gap between the housing 10 and the internal components to a certain extent, reducing the possibility of dust and moisture entering the housing 10 from the button area and protecting components such as the PCB board from environmental influences.

[0255] This design eliminates the need for additional button components (such as silicone buttons or metal springs). Touch functionality is achieved solely through the interaction of conductive foam 320 and button hole 103, simplifying the assembly process and reducing the number of parts and production costs. The conductive foam 320 itself possesses a certain degree of elasticity and cushioning, allowing direct adaptation to the pressing operation of the nameplate 400 without the need for complex structural adaptations, thus improving production efficiency.

[0256] Optionally, the housing 10 has multiple button holes 103, and a voice control hole 104 is provided in the area enclosed by some of the button holes 103.

[0257] Multiple button holes 103 correspond to the physical touch functions of the wired controller (such as mode adjustment, fan speed control, temperature setting, etc.), while the voice control hole 104 corresponds to the voice interaction function (such as voice command input). The layout, partially enclosed by the button holes 103, physically separates the two core control functions on the surface of the housing 10, helping users intuitively distinguish the operating areas and reducing functional confusion. This enclosed structure forms a visual functional cluster, allowing the voice control hole 104 to naturally integrate into the overall layout of the touch area 12. This highlights the independence of the voice function while avoiding visual clutter caused by its dispersed arrangement with the button holes 103, improving the neatness and design of the wired controller. The voice control hole 104 needs to ensure that external sounds can be efficiently transmitted to the microphone assembly inside the wired controller, while minimizing environmental noise interference. Placing it within the area enclosed by the button holes 103 provides some physical protection for the voice hole using the structure of the surrounding button holes 103, reducing the direct entry of dust into the voice hole, minimizing the impact of external impacts on the microphone assembly, and extending the lifespan of the voice function.

[0258] From the perspective of user operating habits, touch buttons and voice control are both active control behaviors. Placing them close together in space conforms to the user's behavior logic of completing multiple operations in a single control area, eliminating the need to move the operation position over a large area on the surface of the casing 10, thus improving ease of use.

[0259] The internal space of the wired controller housing 10 is limited, especially under the requirement of a thin and light design, which necessitates minimizing the space for internal components. By centralizing the voice control hole 104 and the button hole 103 within the enclosed area, the corresponding internal microphone components, button contacts, conductive foam 320, and other structures can be arranged close together, reducing the length of internal wiring harness connections and the risk of structural interference, thus improving space utilization. This centralized layout reduces the complexity of mold design for the housing 10, eliminating the need for a separate clearance structure or reinforcing rib for the voice control hole 104. It allows for unified consideration of the housing 10's strength design with the button hole 103 area, simplifying mold development and production processes.

[0260] Optionally, the wired controller also includes a power board 330, which is connected to the PCB board via pin headers. The power board 330 is equipped with an 1192 communication module and / or a 485 communication module.

[0261] The power board 330 is connected to the PCB board via pin headers, forming a modular structure where the power supply and communication modules are independently managed: the PCB board focuses on core functions such as display driving and touch signal processing, while the power board 330 is responsible for power management and communication interaction. This division of labor ensures that the design, debugging, and upgrade of the two types of functions do not interfere with each other, reducing the overall development difficulty. The 1192 and 485 communication modules are commonly used wired communication interfaces in the air conditioning industry. Integrating them on the power board 330 allows for independent circuit design, reducing electromagnetic interference from the display and touch circuits on the PCB board, ensuring stable communication signal transmission, and reducing the risk of command delay or loss.

[0262] The design supports two communication modules, allowing the wired controller to adapt to the communication protocols of different brands and models of air conditioners: when connecting to air conditioners using the 1192 protocol, the corresponding module is enabled; when connecting to devices using the universal 485 protocol, the 485 module is switched, greatly improving product compatibility and expanding applicable scenarios.

[0263] The power board 330 itself provides power, and the communication module can be directly powered by the power board 330, avoiding the complexity of power lines caused by drawing power from the PCB board. Simultaneously, the pin header connection method achieves separation of power and signal transmission through clear pin definitions (such as power positive and negative, communication signal lines, and ground lines), reducing interference from power fluctuations on communication signals and improving circuit safety. Communication modules (especially the 485 module) may involve external wiring harness connections; integrating them onto the power board 330 allows for centralized design of surge protection and electrostatic discharge (ESD) protection circuits, which work in conjunction with the power supply protection function of the power board 330, enhancing the wired controller's adaptability to external electrical environments and reducing the risk of damage caused by lightning strikes, ESD, etc.

[0264] The power board 330 is connected to the PCB board via a pin header, eliminating the need for complex soldering or wire harness binding, simplifying the production assembly process and reducing human error. Simultaneously, the modular design makes troubleshooting more efficient: if communication functionality is abnormal, the power board 330 can be tested or replaced individually without replacing the entire PCB board, reducing repair costs and time. The standardized pin header interface facilitates automated assembly on the production line, improving mass production efficiency, and providing a convenient component replacement solution for subsequent after-sales maintenance.

[0265] Optionally, the housing 10 protrudes rearward, and the power board 330 is located in the rearward protruding portion of the housing 10.

[0266] While the overall design of the wired controller prioritizes a slim and lightweight profile, the power board 330 may integrate larger or taller components such as capacitors and transformers (especially power boards 330 supporting high-voltage input or multiple communication modules). The rearward protrusion of the housing 10 forms an independent cavity, specifically reserving space for the power board 330 and taller components. This prevents these components from compressing the PCB board, display module 310, and other structures due to height limitations, resolving the conflict between the need for a slim and lightweight design and the height of the components. The protrusion is designed only for the power board 330 area, rather than increasing the overall thickness of the housing 10. This allows the non-protruding areas of the wired controller to maintain a relatively thin profile, achieving a balance between local space optimization and overall slimness, and enhancing the product's refined appearance. The rearward protrusion of the housing 10 provides physical protection for the power board 330, reducing the direct impact of external shocks (such as bumps during installation or pressure during daily use) on the power board 330 and its components, and reducing the risk of components falling off or solder joints loosening. It also provides extra protection for vulnerable communication modules (such as 1192 and 485 modules) on the power board 330.

[0267] The power board 330 generates heat during operation. The independent space formed by the protrusion of the housing 10 reduces direct contact between the power board 330 and components with lower heat generation, such as the PCB board and display module 310, thus reducing the impact of heat conduction on other components. Simultaneously, a small ventilation gap can be reserved inside the housing 10 in the protruding area to assist in heat dissipation of the power board 330 and prevent localized overheating that could lead to performance degradation. The power board 330 involves power conversion and communication signal transmission, and has numerous connection points with high-voltage power supplies or external wiring harnesses. Isolating it within the independent area of ​​the protrusion of the housing 10 reduces electromagnetic interference from electrical signals on the power board 330 to display and touch signals on the PCB board, improving signal transmission stability. It also reduces the risk of external moisture and dust directly contacting the power board 330 through gaps, enhancing electrical safety.

[0268] Wired controllers often need to be embedded in the wall or installed on a flat surface. The rearward protrusion of the housing 10 (i.e., the side facing the mounting surface protrudes) can hide the protruding area within the installation gap (such as the mounting groove reserved in the wall), avoiding the entire wired controller from protruding from the mounting surface due to the thickness of the power board 330, thus ensuring the flatness and aesthetics after installation.

[0269] Optionally, a protrusion 260 is formed on one side of the rear shell, and a protruding mating part 156 is provided on one side of the front shell corresponding to the protrusion 260, with the protrusion 260 being embedded in the protruding mating part 156.

[0270] This design allows for easy separation of the front and rear shells by combining the localized thinning of the front shell with the localized thickening of the rear shell. It also facilitates the installation and positioning of the front and rear shells during assembly.

[0271] Optionally, the PCB board is provided with a positioning angle 317 corresponding to the protruding mating part 156.

[0272] This design incorporates a foolproof approach to PCB installation.

[0273] This disclosure provides an air conditioner that includes the aforementioned wired controller.

[0274] The air conditioner provided in this embodiment includes the above-described wired controller and therefore has the same technical effects as the wired controller described above, which will not be repeated here.

[0275] The foregoing description and accompanying drawings fully illustrate embodiments of the present disclosure to enable those skilled in the art to practice them. Other embodiments may include structural and other changes. The embodiments represent only possible variations. Individual components and functions are optional unless explicitly required, and the order of operation may vary. Parts and features of some embodiments may be included or substituted for parts and features of other embodiments. Embodiments of the present disclosure are not limited to the structures described above and shown in the accompanying drawings, and various modifications and changes may be made without departing from its scope. The scope of the present disclosure is limited only by the appended claims.

Claims

1. A drive-by-wire controller having a narrow bezel, characterized by, The line controller comprises: a front shell comprising a base plate and a plurality of side plates, the base plate and the plurality of side plates enclosing an installation space, the base plate being provided with a display window, a distance between a first side of the display window and a first side plate of the plurality of side plates being less than or equal to 5 mm; a rear shell covering the installation space; a reinforcing portion provided on an inner side of the first side plate, the reinforcing portion forming a clamping groove; a PCB plate provided in the installation space, a first end of the PCB plate being inserted into the clamping groove and a second end of the PCB plate being fixed to the base plate.

2. The drive-by-wire controller of claim 1, wherein, The reinforcing portion comprises: a plurality of first reinforcing ribs provided along a length direction of the first side plate, the first reinforcing ribs extending along a width direction of the first side plate and being provided with an opening, the openings of the plurality of first reinforcing ribs collectively forming the clamping groove.

3. The drive-by-wire controller of claim 2, wherein, The reinforcing portion further comprises: a second reinforcing rib extending along the length direction of the first side plate.

4. The line controller according to claim 3, wherein: the base plate, the first side plate, the first reinforcing ribs and the second reinforcing rib are in an integral structure; and / or the reinforcing portion comprises a plurality of the second reinforcing ribs, the plurality of second reinforcing ribs being provided along the width direction of the first side plate.

5. The line controller according to any one of claims 1 to 4, wherein: a ratio of an area covered by the reinforcing portion to an area of the first side plate is greater than or equal to 0.1 and less than or equal to 0.9; and / or a ratio of a thickness of the reinforcing portion to a thickness of the first side plate is less than or equal to 0.

6.

6. The line controller according to any one of claims 1 to 4, wherein: a distance between an upper end surface of the PCB plate and a first inner wall of the clamping groove is greater than or equal to 0.05 mm; a distance between a lower end surface of the PCB plate and a second inner wall of the clamping groove is less than or equal to 0.1 mm; wherein the first inner wall and the second inner wall are two opposite walls of the clamping groove.

7. The line controller according to claim 6, wherein: the second inner wall of the clamping groove is provided in an inclined manner to allow the PCB to be inserted into the clamping groove in an inclined posture.

8. The line controller according to claim 7, wherein: the first inner wall of the clamping groove is provided in an inclined manner, and a width of the clamping groove gradually decreases from outside to inside.

9. The drive-by-wire controller of any one of claims 1 to 4, wherein, The line controller further comprises: a first limiting portion provided on the first side plate and located at a first end of the clamping groove; a second limiting portion provided on the first side plate and located at a second end of the clamping groove; the first limiting portion and the second limiting portion collectively limiting a position of the PCB plate.

10. An air conditioner characterized by comprising: The air conditioner comprises: an air conditioner body; and the line controller according to any one of claims 1 to 9. ​

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