Illuminated Button Ring Structure for Dead Front HMI Design
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Solution Overview
Problem
Implementing a light ring effect on hardware products, such as buttons, is complicated and costly due to the need for dedicated optical components, and achieving a 'dead front' effect requires additional processing and coatings, which can interfere with the button's function.
Innovation Solution
A button design using a button as a light diffuser with strategically designed gaps and a single light-emitting component, combined with a multi-shot injection molding process, eliminates the need for additional optical components and achieves a uniform light ring effect without visible components when off.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If dedicated optical components (light diffusers, light pipes, light guides) are used to achieve light ring effect, then the illumination quality is improved, but the device complexity and manufacturing cost increase
Solution Approach 1:
The patent merges the button body and light diffuser into a single integrated component. The button is constructed with light-diffusing material that directly forms the light ring effect when illuminated, eliminating the need for separate light diffusers, light pipes, and light guides. This consolidation maintains high illumination quality while significantly reducing device complexity and component count.
Solution Approach 2:
The button serves multiple functions simultaneously: it acts as both the actuable button and the light diffuser for the light ring effect. The button body is constructed from light-diffusing material that performs the optical function traditionally required by dedicated optical components, making the button a multi-functional element that reduces overall system complexity.
2Shape
If additional optical components and coatings are added to achieve dead front effect, then the aesthetic appearance is improved, but the manufacturing cost and process complexity increase
Solution Approach 1:
The cosmetic gap and functional gap are merged into a single tapered gap structure that serves both aesthetic and functional purposes. The gap is larger at the exterior surface to provide the dead front aesthetic effect and smaller near the internal cavity to maintain functionality, eliminating the need for separate cosmetic treatments or additional processing steps.
Solution Approach 2:
The gap width varies locally along its length, being larger at the exterior surface for aesthetic purposes and smaller near the internal cavity for functional purposes. This local variation in gap dimensions achieves both dead front appearance and proper button functionality without requiring additional optical components or surface coatings.
3Area of stationary object
If the button is positioned close to the housing perimeter to maximize space, then the space utilization is improved, but the light ring effect and button function are compromised
Solution Approach 1:
The gap between the button and housing perimeter is segmented into two distinct zones: a cosmetic gap for light transmission and visual effect, and a functional gap for button movement and mechanical function. This segmentation allows the button to be positioned optimally within the available space while maintaining both light ring visibility and button functionality.
Solution Approach 2:
The gap is designed with varying width along its length, creating a tapered profile that transitions from a larger width at the exterior surface to a smaller width near the internal cavity. This dimensional variation allows the button to be positioned close to the housing perimeter for space efficiency while maintaining adequate light transmission path and button movement clearance.
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 reduces complexity and cost while maintaining a visually appealing light ring effect and ensuring functional integrity, applicable to various electronic devices with moving or stationary components.
Implementation Method 1
a light-emitting component electrically coupled to a printed circuit board
Implementation Method 2
a first shot of material constructed from a first light-diffusion grade polycarbonate material configured to uniformly disperse light
Data Source
Figure 1
Figure 2
Figure 3A
AI summary
A hardware product for creating a light ring and a dead front effect. The product may include a housing with an opening. The hardware product may also include a button positioned within the opening and configured to be depressed by a user. The button is constructed using a two-part molding process and includes a first shot and a second shot. The first shot is configured to disperse light around the perimeter shape of the opening. The second shot is constructed from an optically opaque or semi-opaque material. A single light-emitting component electrically coupled to the circuit board provides light for creating the light ring.