Joystick Cap Assembly With Molded Cable for Simpler Sensing
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Solution Overview
Problem
Conventional game controllers incur high manufacturing costs and complex assembly processes due to the use of flexible printed circuit boards with adhered touch-sensitive elements and insulating materials for joysticks.
Innovation Solution
The joystick structure integrates a cable with the key cap through injection molding, using a conductive soft plastic material, simplifying assembly by eliminating the need for separate components and reducing material costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a flexible printed circuit board with a sensing function is used and a double-sided adhesive is used to adhere the touching element, then the joystick structure achieves electrical sensing capability, but the assembling process becomes more complex and manufacturing cost increases
Solution Approach 1:
The patent merges the flexible printed circuit board and the touching element into a single integrated component. The touching element is formed as an integral part of the flexible printed circuit board through injection molding, eliminating the need for separate components and adhesive bonding. This integration simplifies the assembling process while maintaining electrical sensing capability.
Solution Approach 2:
The patent uses composite materials by integrating conductive elements directly into the flexible printed circuit board structure. The flexible printed circuit board is made with conductive traces and touching elements embedded within the same material matrix, allowing it to function as both structural and electrical components without requiring separate adhesive layers.
2Reliability
If a flexible printed circuit board with sensing function is used, then electrical sensing is achieved, but manufacturing cost increases
Solution Approach 1:
The patent combines multiple functions into a single component - the flexible printed circuit board serves as both the electrical connection medium and the touching sensing element. This merging reduces the total number of parts that need to be manufactured, sourced, and assembled, thereby reducing overall manufacturing cost while preserving electrical sensing capability.
Solution Approach 2:
The flexible printed circuit board is designed to perform multiple functions simultaneously: it provides electrical connections, serves as the touching sensing surface, and acts as a structural component of the joystick. This multi-functionality eliminates the need for separate specialized components, reducing manufacturing complexity and cost.
3Strength
If the upper portion of the joystick cap is made of insulating material, then structural integrity is maintained, but the need for flexible printed circuit board with sensing function increases manufacturing cost
Solution Approach 1:
The patent merges the structural joystick cap portion with the electrical sensing function by integrating conductive elements directly into the cap structure. The joystick cap is made with both structural and conductive properties in a single component, eliminating the need for separate flexible printed circuit boards and adhesive layers, thereby reducing manufacturing cost while maintaining structural integrity.
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 integration simplifies the assembly process and lowers manufacturing costs by eliminating the need for separate components and adhesive bonding, while maintaining electrical functionality.
Implementation Method 1
One end of the cable is integrally molded in the fastening portion by an injection molding technology
Implementation Method 2
The key cap is made of a conductive soft plastic material
Data Source
AI summary
A joystick structure includes a key cap, a base, a steering stick unit disposed to a bottom surface of the base, a circuit board and a cable. The key cap has a head portion. A bottom surface of the head portion extends downward to form a fastening portion. The base is disposed to a bottom surface of the key cap. The base has a main portion. A top of the main portion extends upward to form a hollow surrounding portion. The fastening portion is fastened in the surrounding portion. The base has a through hole. The steering stick unit is mounted on a top surface of the circuit board. One end of the cable is integrally molded in the fastening portion. The other end of the cable passes through the through hole, and then the other end of the cable is electrically connected with the circuit board.