Convex Control Panel Assembly for Flexible PCB Connection Stability
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Solution Overview
Problem
The convex shape of modern household appliance control panels creates structural issues for flexible circuit boards, leading to weak or broken connections, which can cause system failure, as they tend to lift off the attached surface due to lack of contact and tension.
Innovation Solution
A support plate with connection units is mounted behind the flexible circuit board to secure it in place, providing tension and maintaining direct contact with the control panel, ensuring continuous operation by accommodating the convex shape and preventing detachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If the control panel has a convex shape for aesthetic purposes, then the appearance is improved, but the flexible circuit board tends to lift off the surface and connection is broken
Solution Approach 1:
A support plate is introduced as an intermediary component between the flexible circuit board and the control panel. The support plate has a convex shape that matches the control panel's convex surface, providing a stable mounting surface that prevents the flexible circuit board from lifting off while maintaining the aesthetic convex shape of the control panel.
Solution Approach 2:
The flexible circuit board is designed as a thin, flexible component that can conform to the convex shape of the control panel when mounted on the support plate. The flexibility allows it to adapt to the curved surface without breaking the connection, while the support plate ensures it remains in contact with the control panel surface.
2Ease of manufacture
If the flexible circuit board is glued directly on the convex surface, then installation is simplified, but the connection becomes weak and breaks due to lifting
Solution Approach 1:
The support plate serves as a mediator between the adhesive and the flexible circuit board. By providing a flat mounting surface on the convex control panel, the support plate allows for more effective adhesive bonding, preventing the circuit board from lifting off while maintaining ease of installation through the simplified mounting process.
3Shape
If force is exerted on the flexible circuit board to acquire the preferred shape, then the shape conformability is improved, but when force is removed the board flattens out and connection is lost
Solution Approach 1:
The support plate is pre-shaped to match the convex form of the control panel before the flexible circuit board is mounted. This preliminary preparation of the mounting surface ensures that when the circuit board is installed, it automatically conforms to the desired shape without requiring continuous force application, and maintains that shape stable over time.
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The present invention relates to a control panel assembly (1) for a household appliance comprising, an outer panel with a convex form, an electronic flexible input/output device (a flexible printed circuit board (7)) to be attached in the inner face of a control panel frame (6), at least one input button connected to the electronic flexible input/output device and a support plate (8) mounted behind the electronic flexible input/output device to secure the flexible input/output device.