Elastomeric Joystick Assembly with Flex-Wall Sealing
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Solution Overview
Problem
Conventional joystick assemblies are complex and require additional reinforcement or support for precise location, which increases costs and complexity, and often lack effective water-resistance and durability in harsh environments.
Innovation Solution
An elastomeric joystick assembly with a core and elastomeric overlay featuring a tactile surface, water-resistant coating, and a flex-wall that locates the joystick relative to the switch panel without additional support, reducing complexity and enhancing durability and water-resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional joystick assemblies use additional reinforcement or support structures for precise location, then positioning accuracy is improved, but device complexity and cost increase
Solution Approach 1:
The elastomeric overlay combines multiple functions into a single integrated component: it provides the tactile surface for user input, creates water-resistant sealing, and locates the joystick core relative to the switch panel through its flex-wall structure. This eliminates the need for separate reinforcement structures or locating mechanisms that would otherwise be required in conventional assemblies.
Solution Approach 2:
The elastomeric overlay serves multiple purposes simultaneously: it acts as a tactile interface layer, a water-resistant barrier, a structural locator for the joystick core, and a flexible mounting solution. This multi-functionality reduces the overall number of components needed while maintaining precise positioning accuracy.
2Strength
If conventional joystick assemblies use additional reinforcement or support structures, then structural strength is improved, but manufacturing cost increases
Solution Approach 1:
The elastomeric overlay integrates structural support, locating, and sealing functions into a single molded component, eliminating the need for multiple separate parts that would require assembly steps, additional fasteners, and alignment procedures. This single-component approach reduces manufacturing complexity and cost while maintaining structural integrity.
Solution Approach 2:
The elastomeric overlay uses a flexible thin-walled structure that provides sufficient structural strength and locating precision without requiring thick reinforcement plates or rigid support structures. The flexibility of the elastomeric material allows it to provide strength while maintaining a lightweight, cost-effective design.
3Quantity of substance
If the flex-wall is made thinner to reduce material usage, then cost is reduced, but water-resistance may be compromised
Solution Approach 1:
The elastomeric overlay utilizes a thin flexible wall structure that provides effective water sealing through its material properties rather than thickness. The elastomeric material's inherent flexibility and sealing capability allow the thin wall to conform to the joystick core and switch panel interface, creating an effective water-resistant barrier without requiring thick material.
Solution Approach 2:
The elastomeric overlay is made from specially formulated elastomeric material that combines flexibility, durability, and water-resistance properties. This composite material approach allows the thin wall to achieve the same or better water-sealing performance as thicker walls made from less optimized materials.
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
The elastomeric joystick assembly provides a rugged, inexpensive, and reliable solution with reduced complexity, improved durability, and effective water-resistance, allowing for precise location and operation in harsh conditions.
Implementation Method 1
The elastomeric overlay can include a tactile surface for a user, a water-resistant coating for a switch panel and a flex-wall disposed between the tactile surface and switch panel coating
Implementation Method 2
When the flex-wall is configured to extend laterally without slack, the flex-wall is largely not under tension or compression when the joystick in its upright or neutral/equilibrium position. Once the joystick is manipulated in a direction of motion, the flex-wall opposite the direction of motion is pulled under tension, preventing the joystick from significant lateral motion relative to the switch panel
Data Source
AI summary
The present invention provides, in some aspects, a rugged and inexpensive joystick assembly comprising a core configured to manipulate a series of switches and located by an elastomeric overlay. The elastomeric overlay can include a tactile surface for a user, a water-resistant coating for a switch panel and a flex-wall disposed between the tactile surface and switch panel coating. The elastomeric overlay can be configured to positively locate the joystick core relative to the switch panel and provide a water-tight seal. The thickness, width and hardness of the flex-wall can be tuned to provide adequate locating strength and resistance to wear.