Appliance control module with in-molded electronics
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Solution Overview
Problem
In-molded electronics in control panels of appliances often require additional connection elements like cables, which increase the overall size and introduce potential failure points due to loose connectors from vibrations.
Innovation Solution
A control module design where conductive ink is embedded in a film that is integrally molded onto the housing, allowing direct connection to a printed circuit board via a header, eliminating the need for separate cables and connectors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If additional connection elements like cables are used to connect in-molded electronics to the circuit board, then the connection can be established, but the overall size of the control panel increases and potential failure points are introduced
Solution Approach 1:
The film is integrally molded onto the housing, merging the film attachment and housing structure into a single integrated component. This eliminates the need for separate connection elements and reduces the overall control panel size while maintaining reliable electrical connections between the conductive ink on the film and the circuit board
Solution Approach 2:
The patent extracts and eliminates the unnecessary cable and connector components from the system. By using direct integral molding, the connection path is simplified from a multi-component assembly to a streamlined integrated structure, removing potential failure points while reducing size
2Reliability
If cables and connectors are used to connect in-molded electronics, then the connection can be established, but the connection becomes susceptible to loosening from vibrations over time
Solution Approach 1:
By integrating the film directly onto the housing through molding, the connection structure becomes a unified assembly that resists vibration-induced loosening. The integral construction eliminates separate connectors that could work loose, creating a vibration-resistant connection between the conductive ink and circuit board
Solution Approach 2:
The film is pre-attached to the housing through integral molding before final assembly, creating a permanent bond that prevents subsequent loosening from vibrations. This preliminary integration ensures connection stability is built into the structure rather than relying on separate fastening elements
3Reliability
If in-molded electronics are connected with additional connection elements, then electrical communication can be established, but the number of components and potential failure points increases
Solution Approach 1:
The film, housing, and connection structure are merged into a single integrally molded component, reducing the total number of parts. This consolidation eliminates multiple connection interfaces and potential failure points while maintaining all necessary electrical communication pathways from the conductive ink to the circuit board
Solution Approach 2:
The integrally molded film structure serves multiple functions simultaneously: it provides the substrate for conductive ink, attaches to the housing, and creates electrical connections. This multi-functionality reduces component count and simplifies the overall system architecture
Data Source
AI summary
A control module of an appliance is provided. The control module includes a housing having a film integrally molded onto an outer surface of the housing. The film includes conductive ink embedded in the film. A header on the film is in electrical communication with the conductive ink embedded in the film. The control module also includes a printed circuit board mounted within the housing proximate an inner surface of the housing. The film is connected to the printed circuit board via the header. With this connection, the printed circuit board is in operative communication with the conductive ink embedded in the film.