Keypad Veneer Inner Recess for Laser-Cut Indicia Aesthetics
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Solution Overview
Problem
The manufacture of aesthetically pleasing wall-mounted load control devices, such as keypads, is hindered by the deformation of metal veneers during laser cutting processes used to create indicia, which diminishes the perceived quality of the outer surface.
Innovation Solution
A recess is formed on the inner surface of the metal veneer with an organic shape and chamfered or rounded edges to minimize deformation and preserve the aesthetic, allowing for laser-cut indicia without compromising the outer surface's smoothness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a veneer is thinned to allow laser cutting of indicia, then the indicia can be formed, but the outer surface deforms and aesthetic quality diminishes
Solution Approach 1:
The invention introduces a third dimension by creating a recess (removing material) from the inner surface of the veneer. This dimensional change allows the laser to cut through the indicia without the need to thin the entire veneer, thereby preserving the outer surface smoothness while enabling the laser cutting process to form the indicia effectively
Solution Approach 2:
The veneer is segmented into different thickness zones: the outer surface maintains its original thickness for aesthetic purposes, while a recess is created in the inner surface to provide localized material removal. This segmentation allows the laser cutting process to operate effectively in the thinned zone without affecting the outer surface quality
2Ease of manufacture
If material is removed from the veneer to form indicia, then the indicia are created, but deformation occurs on the outer surface
Solution Approach 1:
Instead of removing material from the outer surface where it would cause visible deformation, the invention removes material from the inner surface by creating a recess. This dimensional shift in material removal location allows indicia formation without compromising the outer surface shape and aesthetic appearance
Solution Approach 2:
The recess acts as an intermediary structure that facilitates the laser cutting process. By providing a pre-thinned zone through material removal from the inner surface, the recess serves as a mediator that enables effective indicia formation while protecting the outer surface from direct laser-induced deformation
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 effectively prevents deformation and maintains the aesthetic appeal of the veneer's outer surface during the laser cutting process, ensuring a visually appealing and functional load control device.
Implementation Method 1
a portion of a veneer of a faceplate and/or button may need to be thinned to allow for forming the indicia in the veneer via the laser cutting process
Data Source
AI summary
A veneer for a wall-mounted keypad may include indicia that are laser cut therethrough and that are representative of functions that may be performed by the keypad. The veneer may include a recess that extends into an inner surface of the veneer, proximate to the indicia. The recess may be shaped such that a perceived aesthetic of an outer surface of the veneer is preserved during formation of the indicia. The recess may for example have an organic shape defined by a curved outer perimeter that does not define any corners.