Modular Button Assembly Tolerance Compensation
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Solution Overview
Problem
Conventional game controllers with pressure sensors made of soft foam material are prone to accumulated tolerances, making them sensitive to structural changes and difficult to diagnose and replace when broken.
Innovation Solution
A modular button assembly featuring a pedestal with limiting portions, a pressure sensor module with a soft material sensor, and a key cap with active and fixing portions, allowing for reduced tolerances and easier detection and replacement, while maintaining high sensing sensitivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a pressure sensor made of soft foam material is used to achieve strong sensing sensitivity, then the sensing sensitivity is improved, but the controller becomes easily affected by accumulated tolerances among structures
Solution Approach 1:
The button assembly is divided into separate modular components: a button body, a pressure sensor module, and a base. The pressure sensor module is independently mounted in the base and can be replaced without replacing the entire button assembly, allowing for tolerance compensation and easier maintenance while maintaining high sensing sensitivity.
Solution Approach 2:
The base acts as an intermediary component that mounts the pressure sensor module and provides a stable foundation. This separate mounting structure isolates the sensitive pressure sensor from accumulated tolerances in the button body and other upper structures, maintaining reliability while preserving sensing sensitivity.
2Device complexity
If a conventional integrated button assembly is used, then the structure is simple, but when the button assembly is broken it is difficult to distinguish the cause and difficult to replace
Solution Approach 1:
The button assembly is segmented into replaceable modules: the button body, the pressure sensor module, and the base. This modular design maintains relatively simple overall structure while enabling easy diagnosis and replacement of specific faulty components, particularly the pressure sensor module which can be independently replaced without discarding the entire button assembly.
Solution Approach 2:
The modular design allows the pressure sensor module to be discarded and replaced independently when faulty, while the button body and base are recovered and reused. This reduces waste and maintenance costs while improving ease of repair.
3Ease of operation
If the button assembly is pressed to contact the pressure sensor, then the button function is achieved, but accumulated tolerances among structures cause values to be overly changed
Solution Approach 1:
By separating the pressure sensor module from the button body through the base mounting structure, the system allows for independent positioning and tolerance compensation. The base provides a stable reference point that reduces the impact of accumulated tolerances from multiple assembly steps, maintaining manufacturing precision while preserving ease of operation.
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 modular button assembly minimizes accumulated tolerances and enhances sensing sensitivity, enabling easier detection and replacement within the game controller, improving user interaction and durability.
Implementation Method 1
a pressure sensor module (2), a top of the pressure sensor module (2) has a soft material sensor (21), the soft material sensor (21) has an elasticity
Data Source
AI summary
A button assembly adapted for being mounted in a controller includes a pedestal, a pressure sensor module and a key cap. A middle of the pedestal has an accommodating groove penetrating upward through a top surface of the middle of the pedestal. Two opposite sides of the pedestal have two limiting portions oppositely protruded outward. The pressure sensor module is mounted in the accommodating groove of the pedestal. The key cap is covered on the pressure sensor module. A bottom surface of the key cap has a contact portion contacting with the pressure sensor module. Two opposite sides of the key cap have an active portion and a fixing portion protruded outward. The active portion and the fixing portion are mounted to the two limiting portions, respectively. In processes of pressing and releasing the key cap, the active portion move downward and upward with respect to the one limiting portion.