Mitered Plastic Housing for Remote Control with Integrated Venting
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Solution Overview
Problem
Existing plastic housings for electronic devices, such as remote controls, often suffer from issues like burns, inclusions, and burrs that detract from their aesthetic appeal and functionality, particularly due to gaps between form-fitting elements and production-related defects.
Innovation Solution
The design features miter surfaces on the housing parts that provide a positive locking mechanism, allowing for a wider contact surface and precise alignment, with ventilation points strategically placed near the miter surfaces to remove air and prevent burrs from forming, and ejector pins used to clean the mold spaces, ensuring a smooth, burr-free interior.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If form-locking elements are used to enlarge the joining surface, then the contact surface between housing parts is increased, but gaps may remain between housing parts if the elements are not precisely matched
Solution Approach 1:
The patent combines the form-locking elements with the venting function into a single integrated structure. The venting points are formed as recesses in the mold cavities that align with the form-locking elements, allowing air to escape through the same features that provide mechanical interlocking. This eliminates the need for separate venting channels and reduces the number of precision-critical interfaces.
Solution Approach 2:
The patent introduces an intermediary structure - the venting points formed as recesses in the mold cavities - that mediates between the form-locking elements and the air discharge requirement. These recesses provide a controlled pathway for air escape while maintaining the integrity of the form-locking connection, preventing both gaps and air entrapment.
2Productivity
If venting points are placed at miter surfaces to discharge air, then air can escape from mold cavities, but burrs may form at the venting points
Solution Approach 1:
The patent applies local quality by creating recesses specifically at the venting points in the mold cavities. These recesses are localized features that provide air escape pathways without affecting the overall quality of the miter surfaces. The recesses are positioned and dimensioned to allow air discharge while preventing molten material from accumulating and forming burrs.
Solution Approach 2:
Instead of projecting venting elements outward from the miter surfaces (which would create burrs), the patent inverts the approach by creating recesses that draw inward. This inversion allows air to escape through the recesses while the surrounding miter surface remains smooth and burr-free, as the recesses are contained within the housing parts.
3Manufacturing precision
If miter surfaces are used for joining housing parts, then precise alignment and centering are achieved, but air entrapment in mold cavities occurs
Solution Approach 1:
The patent segments the mold cavity ventilation function from the overall miter surface structure. By creating discrete venting points as recesses at specific locations along the miter surfaces, the patent allows air to escape at multiple distributed points without compromising the continuity or precision of the miter joint itself. This segmentation enables both precise alignment and effective air discharge.
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 eliminates gaps and burrs, achieving a seamless, monolithic appearance and enhancing the production process by ensuring precise fitting and removing air effectively, thus improving the aesthetic and functional quality of the plastic housing.
Implementation Method 1
air is discharged from the mold cavities at venting points located at or adjacent to points in the mold cavities at which the mitered surfaces of the housing parts are formed
Data Source
Figure 1
Figure 2a~2c
Figure 3a~3c
AI summary
The invention relates to a plastic housing (2) for electronic devices (1), in particular remote controls, comprising a first housing part (3) and a second housing part (4), wherein the first housing part (3) comprises a joining surface (36) directed towards the second housing part (4) and the second housing part (4) comprises a joining surface (36) directed towards the first housing part (3), wherein the two housing parts (3, 4) are joined together with their joining surfaces (36) abutting each other, and wherein the joining surfaces (36) are designed as mitered surfaces (36).