Elastomeric Switch Assembly with Sealing Layer
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Solution Overview
Problem
Existing programmable button panels (PBPs) in gaming units are complex, prone to mechanical failure, not spill-resistant, and costly due to intricate components, which leads to reduced durability and increased manufacturing expenses.
Innovation Solution
A switch assembly featuring a transparent lens with a hollow interior, an elastomeric switch activated by a planar actuator, and a sealing switch layer to prevent liquid ingress and simplify design, using fewer and more durable components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional switch assemblies with multiple intricate components (actuators, optical sensors, mechanical springs) are used, then the switch assembly can achieve switching functionality, but the device complexity increases and reliability decreases due to more potential failure points
Solution Approach 1:
The patent combines the actuator, optical sensor, and switch components into a single integrated elastomeric switch assembly. The elastomeric material itself serves as both the actuator (through its deformable key) and the sensor (through embedded carbon pills that detect contact), eliminating the need for separate mechanical components and reducing overall device complexity while improving reliability.
Solution Approach 2:
The patent replaces traditional mechanical switching mechanisms (mechanical contacts, springs, levers) with an elastomeric-based system that uses material deformation and electrical conductivity changes. The carbon pills embedded in the elastomeric key provide electrical switching without mechanical contact wear, significantly improving durability and reducing the number of moving parts.
2Ease of manufacture
If traditional switch assemblies with exposed components are used, then the switch assembly can be manufactured, but manufacturing precision requirements increase and production costs rise due to intricate component assembly
Solution Approach 1:
The integration of multiple components into a single elastomeric switch assembly eliminates the need for precise alignment of separate parts during manufacturing. The elastomeric key with embedded carbon pills can be manufactured as a single molded component, dramatically simplifying the manufacturing process and reducing the need for high-precision assembly operations.
Solution Approach 2:
The patent changes the manufacturing approach from assembling multiple metal and plastic components to molding a single elastomeric component with embedded conductive elements. This parameter change in material state and manufacturing process significantly reduces manufacturing precision requirements while maintaining functional performance.
3Reliability
If traditional switch assemblies without sealing are used, then the design remains simple, but the switch assembly becomes vulnerable to liquid damage and requires more frequent maintenance
Solution Approach 1:
The elastomeric switch assembly itself acts as a flexible sealing barrier. The elastomeric material forms a continuous, flexible shell that encloses the electrical components (PCB, carbon pills, LED), providing spill resistance without requiring additional rigid sealing structures. This flexible sealing approach maintains simplicity while improving durability.
4Ease of manufacture
If complex switch assemblies with multiple components are used, then the switching function is achieved, but the cost of manufacturing increases due to intricate components and assembly processes
Solution Approach 1:
The patent merges multiple discrete components (actuator, sensor, switch, seal) into a single elastomeric assembly that can be manufactured in one molding process with embedded conductive elements. This consolidation dramatically reduces part count, eliminates multiple assembly steps, and lowers production costs while maintaining all necessary functions.
Solution Approach 2:
The patent uses composite materials, specifically carbon pills embedded in elastomeric material, to create a component that simultaneously provides mechanical actuation, electrical conductivity, and sealing properties. This multi-functional composite approach eliminates the need for multiple separate components and reduces manufacturing complexity.
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 solution provides a durable, cost-effective, and easy-to-clean switch assembly resistant to spills, with a longer lifespan and reduced maintenance costs, suitable for gaming environments.
Implementation Method 1
an elastomeric switch member formed within the sealing switch layer that is actuatable by the movement of the lens for engagement with the printed circuit board
Data Source
AI summary
The present disclosure provides a switch assembly including a lens having a hollow interior, a display at least partially received within the hollow interior of the lens, an actuator moveably engageable by the lens, and an elastomeric switch activatable by the actuator in response to movement of the lens. The elastomeric switch may include a circuit assembly, a sealing switch layer disposed over the circuit assembly, and an elastomeric switch member formed within the sealing switch layer that is actuatable by the movement of the lens for engagement with the circuit assembly.