In-Molded Control Panel Assembly With Encapsulated Printed Circuit

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Solution Overview

Problem

Conventional control panel assemblies are complex and costly due to multiple components and potential failure points, especially in small or uniquely shaped products with complex controls, leading to high manufacturing expenses and reliability issues.

Innovation Solution

A simplified control panel assembly is created by bonding two film layers to either side of an injection molded resin, with one film featuring an in-molded decorative surface and the other a printed circuit containing capacitive touch sensors, electronic components, and a single connector for direct interconnection, fully encapsulated in resin for protection.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If conventional control panel assemblies use multiple separate components (switches, indicators, circuit boards, interconnect wires), then the control panel can provide complex controls and indicators, but the assembly complexity and manufacturing cost increase significantly

Engineering Contradiction:

Improvecomplex controls and indicatorsVSAvoidassembly complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent merges multiple separate components (control panel housing, circuit board, switches, indicators, and interconnect wires) into a single integrated injection-molded assembly. The circuit board is molded directly into the control panel housing, and all interconnects are built-in during the molding process, eliminating the need for separate assembly steps and reducing the number of parts while maintaining full functionality.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The injection-molded control panel assembly serves multiple functions simultaneously: it provides structural housing, integrates circuit board mounting, incorporates switches and indicators, and includes all necessary interconnects. This multi-functional design allows a single component to replace what previously required multiple separate parts.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Adaptability or versatility

If conventional control panel assemblies use multiple separate components and interconnects, then the control panel can be assembled with various controls and indicators, but the number of potential failure points increases

Engineering Contradiction:

Improvecontrols and indicators functionalityVSAvoidfailure points

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

By combining all components into a single molded assembly, the patent eliminates multiple interfaces and connection points between separate parts. The circuit board is permanently integrated into the housing, and all interconnects are built-in during molding, removing the possibility of connection failures that occur with separate assemblies.

Inventive Principle:

Principle #5Merging (Combining)

3Adaptability or versatility

If conventional control panel assemblies use multiple separate components, then the control panel can provide comprehensive control functions, but the manufacturing cost increases due to multiple components and assembly steps

Engineering Contradiction:

Improvecontrol functionsVSAvoidmanufacturing cost

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The patent consolidates multiple manufacturing steps into a single injection molding process. The housing, circuit board, switches, indicators, and interconnects are all formed in one molding cycle, eliminating the need for separate manufacturing and assembly operations for each component.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The circuit board and all interconnects are pre-integrated into the housing during the molding process itself, rather than being assembled afterward. This preliminary integration during manufacturing reduces both the number of manufacturing steps and the associated labor and overhead costs.

Inventive Principle:

Principle #10Preliminary action

4Adaptability or versatility

If conventional control panel assemblies use separate circuit boards and interconnects, then the control panel can interface with various control boards, but the interconnects and associated assembly create complexity and cost

Engineering Contradiction:

Improveinterface capabilityVSAvoidinterconnect complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent integrates all interconnect functions directly into the molded control panel assembly. The circuit board is molded into the housing with built-in connection points, eliminating the need for separate wire harnesses and connectors while maintaining the ability to interface with external control boards.

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentUS9615468B2Injection molded control panel with in-molded decorated plastic film

Publication Date: 2017.04.04 E2IP TECH INC

AI summary

Provided are systems and methods for a control assembly including: a first film that is in-molded that includes decorative graphics, a front surface and a rear surface; and a second film molded to the rear surface of the first film having a printed circuit that includes sensors, control circuits and interconnects and a front and rear surface.