Electrode Sheet Passage for 3D Curved Capacitive Switch
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Solution Overview
Problem
In electrostatic-capacitance type operation devices, electrode sheets face wrinkling or breaking during molding when trying to achieve a three-dimensional curved surface, limiting design freedom and increasing manufacturing costs and defects.
Innovation Solution
A thermoplastic synthetic resin sheet electrode sheet with a through hole, allowing molten resin to flow and form a three-dimensional curved surface without additional processing, ensuring proper contact and integration during insert-molding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the electrode sheet is not processed at all, then the manufacturing process remains simple, but the electrode sheet is likely to be wrinkled or broken during molding
Solution Approach 1:
A passage is formed in advance on the electrode sheet at the position corresponding to the gate. This preliminary action allows molten resin to flow through the electrode sheet during molding, preventing wrinkles and breaks while maintaining manufacturing simplicity by integrating the passage formation into the electrode sheet manufacturing process
2Reliability
If slits are provided on the electrode sheet to prevent wrinkles, then the electrode sheet integrity is improved, but the design freedom of the electrode sheet is limited
Solution Approach 1:
Instead of providing slits across the entire electrode sheet, a passage is formed only at the specific location corresponding to the gate. This localized approach prevents wrinkles and breaks only where needed during molding, while preserving the design freedom and appearance of the rest of the electrode sheet
3Manufacturing precision
If the electrode sheet is shaped in advance by vacuum compressed air molding, then the electrode sheet can imitate the three-dimensional curved surface, but the manufacturing cost increases and defective products increase
Solution Approach 1:
The electrode sheet itself serves the dual function of being both the operational electrode component and the element that imitates the three-dimensional curved surface. By forming a passage and allowing molten resin to flow through, the electrode sheet achieves shape adaptation without requiring separate vacuum molding processes, thereby reducing manufacturing complexity and defects
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
Enables the creation of electrostatic-capacitance type operation devices with enhanced design freedom and reduced manufacturing complexity, avoiding the need for slits and minimizing defects, while maintaining sensitivity and durability.
Implementation Method 1
a thermoplastic synthetic resin sheet which outputs an electric signal according to the amount of change of electrostatic capacitance generated by contact operation with respect to the operation surface
Implementation Method 2
a passage is formed on the electrode sheet so as to allow a molten resin flowing in through a gate formed in a die which comes into contact with the other surface of the electrode sheet during molding to pass toward one surface side of the electrode sheet
Data Source
AI summary
The resin molded article is molded by using an electrode sheet as an insert in a state where one surface of the electrode sheet is closely attached to an inner surface which serves as the inner side of the operation surface. The electrode sheet is formed by using, as a base material, a thermoplastic synthetic resin sheet which outputs an electrical signal according to the amount of change of electrostatic capacitance generated by a contact operation with respect to the operation surface. At least a whole or a part of the inner surface is formed in a three-dimensionally curved surface, and a passage is formed in the electrode sheet so as to allow a molten resin following in through a gate formed in a die which comes into contact with the other surface of the electrode sheet during molding to pass toward one surface side of the electrode sheet.