Vehicle Card Key Switchboard Segmentation
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Solution Overview
Problem
Existing vehicle card keys face limitations in slimming due to the thickness required for housing, tact switches, and light-emitting elements, and are prone to faults from overflow of injected material during molding.
Innovation Solution
A vehicle card key design featuring a flexible printed circuit board for switches and light-emitting diodes, mounted on a separate switchboard part, which is layered inside the housing, allowing for a thinner profile and simplified sheet structure, with a reinforcing assembly and non-molded parts to prevent material overflow and interference.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple sheet members are layered on the front surface part of the circuit board to prevent injected material interference, then the tact switches and light-emitting elements are protected, but the card key thickness increases and the sheet structure becomes complex
Solution Approach 1:
The circuit board is divided into two separate parts: the mainboard part containing the RFID electronic elements, and the switchboard part containing the tact switches and light-emitting elements. This segmentation allows the housing to be molded separately for each part, eliminating the need for multiple protective sheets while maintaining element protection and reducing overall thickness.
Solution Approach 2:
The switchboard part with tact switches and light-emitting elements is extracted from the mainboard part and positioned in a separate location within the housing. This extraction allows the housing to be molded without injected material interfering with the electronic elements, eliminating the need for protective sheets and reducing card key thickness.
2Reliability
If multiple sheet members are layered on the front surface part of the circuit board, then the tact switches and light-emitting elements are protected, but the sheet structure becomes complex and productivity decreases
Solution Approach 1:
The circuit board is divided into two separate parts: the mainboard part containing the RFID electronic elements, and the switchboard part containing the tact switches and light-emitting elements. This segmentation allows the housing to be molded separately for each part, eliminating the need for multiple protective sheets while maintaining element protection and reducing overall thickness.
Solution Approach 2:
The mainboard part and switchboard part are integrated into a single housing structure through injection molding, eliminating the need for separate protective sheets. This merging simplifies the overall structure and reduces the number of assembly steps, thereby improving productivity.
3Strength
If the housing part is molded to cover the entire front surface part of the circuit board, then structural integrity is improved, but injected material may overflow and cause faults in electronic elements
Solution Approach 1:
The circuit board is divided into two separate parts: the mainboard part containing the RFID electronic elements, and the switchboard part containing the tact switches and light-emitting elements. This segmentation allows the housing to be molded separately for each part, eliminating the need for protective sheets while maintaining element protection and reducing overall thickness.
Solution Approach 2:
The switchboard part with tact switches and light-emitting elements is extracted from the mainboard part and positioned in a separate location within the housing. This extraction allows the housing to be molded without injected material interfering with the electronic elements, eliminating the need for protective sheets and reducing card key thickness.
Data Source
AI summary
A vehicle card key, includes: a mainboard part on which an electronic element for wireless transmitting/receiving with a vehicle is mounted; a connector part formed on the mainboard part; a housing part which covers the mainboard part avoiding the connector part; and a switchboard part which has at least one among a switch and light-emitting diode mounted thereon, and which is layered on the mainboard part and is connected to the connector part.