Flexible Shell Key Fob Snap-Fit Housing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing remote keyless entry key fobs are prone to breakage due to brittleness and have labor-intensive assembly processes requiring alignment of multiple components.
Innovation Solution
A key fob design featuring a flexible shell with a snap-fit engagement mechanism for a rigid housing, eliminating the need for a two-part housing and ensuring secure retention of the circuit board, with user-actuatable elements for signal initiation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a two-part plastic housing is used in known key fobs, then the housing can be assembled with multiple components, but the housing becomes prone to breakage due to brittleness and excessive force
Solution Approach 1:
The patent replaces the rigid two-part plastic housing with a single-piece flexible rubber housing that completely surrounds and protects the circuit board. This flexible material eliminates breakage issues while maintaining protective enclosure functionality, directly resolving the contradiction between manufacturing ease and durability.
2Device complexity
If a two-part housing with switch pad and circuit board alignment is used, then the housing can be assembled with multiple components, but the assembly becomes labor intensive requiring precise alignment
Solution Approach 1:
The patent merges the housing, switch pad, and circuit board into a simplified structure where the flexible housing completely surrounds the circuit board. This eliminates the need for precise alignment of multiple components during assembly, as the flexible material naturally conforms and secures internal components, directly resolving the contradiction between device complexity and assembly productivity.
3Strength
If a rigid housing is used to protect the circuit board, then the housing provides structural support, but the housing becomes subject to breakage
Solution Approach 1:
The patent employs a flexible rubber housing that completely surrounds the circuit board, providing structural support while being inherently resistant to breakage. The flexibility of the material allows it to absorb impacts and forces that would cause rigid housings to fracture, directly resolving the contradiction between strength and reliability.
Data Source
AI summary
A key fob for keyless entry into an automobile includes a substantially rigid housing having an outer surface with a ridge or a recess. Signal transmission circuitry is disposed within the housing and is operable to transmit a signal to the automobile. A flexible shell includes a cavity in which the housing is at least partially received. A rim is engaged with the ridge or recess of the housing such that the shell is secured to the housing.