Converter Cover with Embedded Printed User Interface

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Solution Overview

Problem

Conventional converter devices require separate user interfaces and additional structural components for attachment, leading to increased space and manufacturing complexity, as well as higher costs due to traditional circuit board manufacturing methods.

Innovation Solution

Embedding printed electrical components, including displays, push buttons, and sensors, directly into the converter's plastic cover using injection molding, eliminating the need for a separate user interface and simplifying the structure by integrating these components into the cover's design.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If traditional separate user interface components are used, then the converter can perform user interaction functions, but the device complexity and manufacturing cost increase

Engineering Contradiction:

Improveuser interface functionalityVSAvoidstructure complexity

Core Design Contradiction:

Ease of operationVSDevice complexity

Solution Approach 1:

The patent merges the user interface components (display, buttons, indicators) directly into the cover structure of the converter. The cover serves dual purposes: as the protective enclosure and as the housing for user interface elements. This integration eliminates the need for separate user interface assemblies and reduces the number of attachment points required.

Inventive Principle:

Principle #5Merging (Combining)

2Ease of operation

If traditional separate user interface components are used, then the converter can perform user interaction functions, but the manufacturing cost increases

Engineering Contradiction:

Improveuser interface functionalityVSAvoidmanufacturing cost

Core Design Contradiction:

Ease of operationVSEase of manufacture

Solution Approach 1:

The user interface elements are manufactured as an integrated part of the cover using the same injection molding process. This consolidation reduces the total number of parts that need to be manufactured, stored, and assembled, thereby lowering manufacturing costs.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The cover is designed to serve multiple functions simultaneously: structural enclosure, mounting surface for electrical components, and housing for user interface elements. This multi-functionality reduces the overall component count and simplifies the bill of materials.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Ease of operation

If traditional separate user interface components are used, then the converter can perform user interaction functions, but the space required inside the converter increases

Engineering Contradiction:

Improveuser interface functionalityVSAvoidinternal space

Core Design Contradiction:

Ease of operationVSVolume of stationary object

Solution Approach 1:

By integrating the user interface components into the cover, the patent eliminates the need for separate mounting spaces for displays, buttons, and indicators. The cover itself becomes the mounting structure, freeing up internal space for other converter components.

Inventive Principle:

Principle #5Merging (Combining)

4Ease of manufacture

If traditional circuit board manufacturing methods are used, then electrical components can be manufactured, but the manufacturing complexity and cost increase

Engineering Contradiction:

Improvecomponent manufacturingVSAvoidmanufacturing process complexity

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The patent combines the manufacturing of the cover and user interface components into a single injection molding process. This eliminates the need for separate circuit board manufacturing, assembly, and attachment operations, thereby reducing manufacturing process complexity.

Inventive Principle:

Principle #5Merging (Combining)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This approach simplifies the converter's structure, reduces manufacturing complexity, and saves space by integrating user interface components into the cover, enabling a more robust and cost-effective design while allowing for 3D shapes and wireless communication capabilities.

Implementation Method 1

Embedding printed electrical components, including displays, push buttons, and sensors, directly into the converter's plastic cover using injection molding

Methodology Applied

Scientific EffectInjection molding:

Data Source

PatentUS11444544B2Converter

Publication Date: 2022.09.13 ABB (SCHWEIZ) AG

AI summary

A converter and a method of manufacturing a converter. The converter includes electrical components and a cover enclosing a first group of the electrical components of the converter, wherein a second group of the electrical components are printed electrical components which are embedded in the cover of the converter. The cover of the converter includes a user interface, and the user interface includes printed electrical components from the second group of electrical components.