Control Element with Raised Structural Elements via Stencil Printing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for producing touch-sensitive operating elements, such as those used in motor vehicles, often result in structural elements with irregular surfaces and uneven edges due to the use of screen printing processes, which are not suitable for creating well-defined, raised features that can serve as effective tactile aids.
Innovation Solution
A method involving the use of an inherently rigid template with recesses to press a pasty material onto a carrier plate, allowing for the formation of raised structural elements with clean, defined edges and adjustable height, free from fabric-related irregularities, using a ceramic material for enhanced durability and a metal sheet template for precise cutouts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If screen printing process is used to apply pasty material to carrier plate, then production efficiency is improved, but manufacturing precision deteriorates due to irregular surfaces and uneven edges
Solution Approach 1:
The invention extracts and removes the problematic screen mesh from the printing process, using only the stencil template with recesses. This eliminates the source of surface irregularities (threads and mesh) while maintaining the efficiency of the printing process. The pasty material is pressed directly through recesses in the stencil without passing through a screen mesh, thus achieving both high productivity and smooth surface finish.
Solution Approach 2:
The stencil template is segmented into multiple recesses, each defining a specific structural element. This segmentation allows for precise control over the shape and position of each element while maintaining overall production efficiency. Each recess acts as an independent forming cavity, ensuring clean edges and consistent geometry for each structural element.
2Ease of manufacture
If screen printing process is used, then ease of manufacture is improved, but manufacturing precision deteriorates due to frayed edges and irregular contours
Solution Approach 1:
The screen mesh component is completely removed from the manufacturing process. Instead of using a traditional screen printing method where material passes through a mesh, the invention uses a stencil template with open recesses that directly define the structural elements. This extraction eliminates the source of frayed edges and irregular contours while keeping the process simple and easy to manufacture.
3Ease of operation
If thicker pasty material is used to increase height of structural elements, then the tactile aid function is improved, but manufacturing precision deteriorates due to increased surface irregularities
Solution Approach 1:
By removing the screen mesh from the process, the invention eliminates the constraint that limited paste thickness. Without the mesh to create surface irregularities, thicker pasty material can be applied through the stencil recesses, achieving greater structural element height and improved tactile functionality while maintaining smooth, uniform surfaces.
Solution Approach 2:
The invention changes the parameter of paste thickness without the negative consequences of traditional screen printing. The stencil template allows for variable thickness control of the pasty material, enabling optimization of tactile aid function (higher elements) while avoiding surface irregularities that would normally accompany thicker material application.
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
The invention relates to a method for producing a control element (30) having a touch-enabled surface (38), in which a paste-like material (48) is applied on a carrier plate (36). At least one raised structure element (32, 34) is formed by the paste-like material (48) on the carrier plate (36). For this purpose, a stencil (42) having inherent stiffness is arranged above the carrier plate (36) and the paste-like material (48) is pushed through at least one recess (44) in the stencil (42). The invention further relates to a control element (30).