Electronic Subassembly Assembly for Personal Care Products
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Solution Overview
Problem
Existing electronic personal care products, such as razors, face challenges in reliably assembling and sealing electronic components against water ingress due to their delicate nature and the need for compact design, which can lead to failure when exposed to wet environments.
Innovation Solution
A method involving a hollow housing with a first circuit board inserted through one end and a second circuit board subassembly inserted through the other end, where the first circuit board is connected to the second within the housing, using a rigid end and flexible portion configuration, and a plug molded around the rigid end for sealing, allowing for precise alignment and sealing without complex fixtures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If electronic components are made small to fit within personal care product, then device compactness is improved, but component reliability deteriorates as delicate components break easily
Solution Approach 1:
The housing is divided into multiple segments (first housing portion, second housing portion, end cap) that can be assembled separately. Circuit boards are segmented into first and second circuit boards with distinct functions. This segmentation allows each component to be optimized independently for both size and reliability, with robust connection interfaces between segments.
Solution Approach 2:
The patent implements nested arrangement where the first circuit board is positioned within the first housing portion and the second circuit board within the second housing portion, with both nested within the overall housing structure. The end cap nests over the second housing portion to provide sealing. This nested configuration maximizes space utilization while maintaining component integrity.
2Reliability
If electronic components are sealed against water ingress, then reliability in wet environment is improved, but assembly complexity increases
Solution Approach 1:
The patent merges the sealing function into the structural components themselves. The end cap is integrated with sealing features that combine structural support and water protection functions. The housing portions are designed with integrated sealing interfaces rather than separate sealing components, simplifying the assembly process while maintaining water resistance.
Solution Approach 2:
The housing portions serve multiple functions: structural support, component mounting, and water sealing. The end cap provides both closure and sealing functions. This multi-functionality reduces the number of separate components needed, thereby simplifying assembly while achieving reliable water protection.
3Manufacturing precision
If circuit boards are connected within confined chamber, then connection precision is improved, but assembly difficulty increases due to limited access
Solution Approach 1:
The patent implements preliminary positioning features on the housing portions and circuit boards that guide alignment before final connection. Mounting features and connection interfaces are pre-configured to ensure precise alignment during assembly, eliminating the need for complex adjustment procedures within the confined chamber.
Solution Approach 2:
The housing portions and circuit boards incorporate self-aligning features that automatically position components correctly during assembly. The connection interfaces are designed to self-guide and self-lock, allowing precise connections to be made without requiring complex external fixtures or manual adjustment, thereby improving assembly ease while maintaining precision.
Data Source
AI summary
A method of assembling an electronic subassembly for a personal care product by manufacturing a hollow housing defining a chamber having a first open end and an opposing second open end. A rigid end of a first circuit board is inserted into the first open end of the housing. A second circuit board subassembly having a second circuit board is inserted into the chamber through the second open end. The first circuit board is connected to the second circuit board within the chamber of the housing.