In-Molded Control Panel Assembly With Encapsulated Internal Connector

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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, which makes them prone to failures and expensive to manufacture.

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 having a printed circuit and surface-mounted electronic components, and the other film decorated with capacitive touch sensors and other features, allowing for total encapsulation and direct connection to a control board or power source.

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 control functions, but the assembly complexity and manufacturing cost increase significantly

Engineering Contradiction:

Improvecontrol functionsVSAvoidassembly complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent combines multiple separate components (switches, indicators, circuit board, interconnect wires) into a single integrated control panel assembly. The circuit board is directly mounted within the control panel housing with switches and indicators attached, eliminating the need for separate interconnect wires and reducing the number of assembly steps. This merging approach maintains full control functionality while significantly reducing assembly complexity.

Inventive Principle:

Principle #5Merging (Combining)

2Adaptability or versatility

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

Engineering Contradiction:

Improvecontrol functionsVSAvoidfailure points

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

By integrating the circuit board, switches, indicators, and housing into a single assembly, the patent eliminates multiple interconnect interfaces that could fail. The direct mounting of the circuit board within the housing and the attachment of switches and indicators to the same structure removes the need for separate wiring connections, thereby reducing the number of potential failure points while maintaining all control functions.

Inventive Principle:

Principle #5Merging (Combining)

3Adaptability or versatility

If conventional control panel assemblies use multiple separate components and interconnects, then control functions can be implemented, but manufacturing cost increases

Engineering Contradiction:

Improvecontrol functionsVSAvoidmanufacturing cost

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The patent reduces manufacturing cost by consolidating multiple components into a single integrated assembly. The circuit board is directly mounted within the control panel housing with switches and indicators attached, eliminating the need for separate interconnect wires and reducing the number of parts that need to be manufactured, inventoried, and assembled. This approach maintains full control functionality while significantly reducing manufacturing complexity and cost.

Inventive Principle:

Principle #5Merging (Combining)

4Ease of repair

If conventional control panels use separate housing and control assembly, then components can be accessed for repair, but the overall assembly complexity increases

Engineering Contradiction:

Improvecomponent accessibilityVSAvoidassembly structure

Core Design Contradiction:

Ease of repairVSDevice complexity

Solution Approach 1:

The patent maintains a separable design where the control panel assembly can be removed as a unit from the housing, allowing for easy replacement and repair. The integrated assembly approach means that the entire control unit (housing with circuit board, switches, and indicators) can be treated as a single module that is either fully functional or fully replaced, simplifying repair procedures while maintaining the ability to access and service the control functions.

Inventive Principle:

Principle #1Segmentation

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

This solution reduces complexity and cost, enhances reliability by protecting components from moisture and physical damage, and results in a more robust and durable product with fewer potential failure points, while allowing for easier assembly and a thinner form factor.

Implementation Method 1

molten resin is injected in between the 2 films completely encapsulating both the second surface decoration on the A side film and the conductive circuit with the mounted components on the B side of the molded article

Methodology Applied

Scientific EffectInjection molding:

Data Source

PatentUS9030837B2Injection molded control panel with in-molded decorated plastic film that includes an internal connector

Publication Date: 2015.05.12 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; and an internal connector.