Integrated Reflector Cup Console Assembly for Brighter PCB Displays
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Solution Overview
Problem
Current home appliance user interfaces and display assemblies are complex and costly to assemble, with separate components for the fascia, PCB assembly, and reflector cups, leading to increased labor costs and potential quality issues.
Innovation Solution
Integration of light reflector cups into the console shell of home appliances, such as laundry treating machines, to directly reflect light from LEDs through holes in the PCB, enhancing brightness and simplifying assembly by reducing parts complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of repair
If separate components for fascia, PCB assembly, and reflector cups are used, then ease of repair is improved, but device complexity increases and manufacturing cost increases
Solution Approach 1:
The patent combines the reflector cup and fascia into a single integrated component. The reflector cup is formed as an integral part of the fascia assembly, eliminating the need for separate reflector cup components. This integration reduces the total number of parts, simplifies assembly, and lowers manufacturing costs while maintaining the ability to service the entire display assembly as a unit.
2Adaptability or versatility
If separate components for fascia, PCB assembly, and reflector cups are used, then adaptability is improved, but productivity decreases due to increased assembly complexity
Solution Approach 1:
The integration of the reflector cup into the fascia creates a pre-assembled unit that can be easily adapted to different display configurations. This integrated assembly reduces the number of discrete parts that need to be handled and assembled, thereby increasing production efficiency and productivity while maintaining design flexibility for different appliance applications.
3Ease of manufacture
If integrated light reflector cups are used, then manufacturing cost decreases and productivity increases, but ease of repair worsens
Solution Approach 1:
The patent integrates the reflector cup into the fascia assembly, which simplifies the manufacturing process by reducing the number of separate components that need to be produced and assembled. This integration lowers manufacturing costs and increases productivity. For repair, the entire integrated assembly can be replaced as a single unit, which simplifies the repair process despite the internal integration of components.
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 integrated light reflector cups provide a cost-effective and efficient method for achieving bright, uniform illumination while streamlining the assembly process, reducing labor costs and improving the quality of the display.
Implementation Method 1
integrated light reflector cups... and light emitting diodes (LEDs) emitting light into at least some of the integrated light reflector cups
Data Source
AI summary
A console assembly for an appliance has a console shell having a front surface with integrated light reflector cups, and a printed circuit board (PCB) mounted to the console shell and having light emitting diodes (LEDs) emitting light into at least some of the integrated light reflector cups.