Illuminated 3D Switch Icon Structure for Better Visibility
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Solution Overview
Problem
Control icons on moving switches are typically two-dimensional and lack aesthetic appeal, making them less visually engaging.
Innovation Solution
A three-dimensional icon is created within a non-moving switch assembly, illuminated by a device such as an LED, and molded into a polycarbonate substrate layer with a clear polyurethane layer to enhance visibility and aesthetic appeal, using techniques like sub-surface laser engraving or capacitive sensors integrated with a printed circuit board.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If a two-dimensional icon is used on a moving switch, then the manufacturing process is simple, but the aesthetic appeal and visual engagement are insufficient
Solution Approach 1:
The patent transitions from two-dimensional icons to three-dimensional icons by molding raised features directly into the polycarbonate substrate layer. This dimensional enhancement provides aesthetic appeal and tactile feedback while integrating the icon structure into the switch assembly itself, avoiding the need for separate icon components.
Solution Approach 2:
The icon features are merged with the polycarbonate substrate layer through direct molding, creating an integrated structure where the icon and switch housing become a single component. This reduces assembly complexity despite the enhanced three-dimensional design.
2Shape
If a three-dimensional icon is molded into the polycarbonate substrate layer, then the aesthetic appeal is enhanced, but the manufacturing process becomes more complex
Solution Approach 1:
The three-dimensional icon features are created during the initial injection molding process of the polycarbonate substrate layer, rather than requiring subsequent machining or assembly steps. The mold cavity includes the icon features as integral parts, so the aesthetic enhancement is achieved during the primary manufacturing operation.
3Illumination intensity
If the icon is illuminated from behind, then the visibility and aesthetic appeal are improved, but the device complexity increases
Solution Approach 1:
The illumination system uses the switch housing itself as the light guide structure. The polycarbonate substrate layer with its three-dimensional icon features acts as both the structural component and the light guiding element, eliminating the need for separate light guides or complex illumination assemblies. The housing geometry directs light to illuminate the icon effectively.
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 more aesthetically pleasing and visually engaging control icon that is visible on the exterior surface when illuminated, enhancing user experience, particularly in vehicle interiors.
Implementation Method 1
a device for illuminating the three dimensional icon, wherein illumination of the three dimensional icon by the device causes the three dimensional icon to be visible on an exterior surface of the assembly
Implementation Method 2
a laser is focused on a very specific point in the three dimensional volume of plastic and a void is created at that point in space
Data Source
AI summary
An assembly including a three dimensional icon defined within an interior of the assembly; the assembly including a non-moveable switch; a device for illuminating the three dimensional icon, wherein illumination of the three dimensional icon by the device causes the three dimensional icon to be visible on an exterior surface of the assembly.