Modular Button Assembly Reducing Tolerance Accumulation
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Solution Overview
Problem
Conventional game controllers experience issues with accumulated tolerances affecting pressure sensing accuracy and difficulty in diagnosing and replacing broken button assemblies, as they are often influenced by multiple structural components.
Innovation Solution
A modular button assembly design featuring a pedestal, pressure sensor module, and key cap with limiting and active portions, utilizing a soft material sensor for enhanced sensitivity and reduced tolerances, allowing for easy detection and replacement, and integration with a fastening frame and circuit board for flexible assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a conventional button assembly with pressure sensor is used, then the button assembly can detect pressure, but accumulated tolerances from multiple structural components cause values to be overly changed and sensing accuracy deteriorates
Solution Approach 1:
The button assembly is divided into independent modular components: key cap, limiting portions, pressure sensor module, and pedestal. Each component can be manufactured separately with controlled tolerances and then assembled, preventing the accumulation of tolerances that would occur in a monolithic structure. The pressure sensor module is specifically isolated as a separate functional unit.
Solution Approach 2:
A soft material layer is introduced as an intermediary between the key cap and the pressure sensor module. This soft material serves as a mediator that transmits pressure forces while compensating for minor dimensional variations and tolerances, thereby maintaining sensing accuracy despite variations in the rigid structural components.
2Ease of repair
If a conventional integrated button assembly is used, then the structure is compact, but when broken it is hard to distinguish the cause and difficult to replace
Solution Approach 1:
The button assembly is segmented into distinct functional modules (key cap, limiting portions, pressure sensor module, pedestal) that can be independently manufactured, tested, and replaced. This modularity allows faulty components to be identified and replaced without replacing the entire assembly, significantly improving repairability.
Solution Approach 2:
The pressure sensor module is designed as a universal component that can be applied across different button assembly configurations and game controller models. This standardization allows the same pressure sensor module to be used in various applications, simplifying inventory management and replacement procedures.
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 reduces accumulated tolerances and enhances sensing sensitivity, enabling precise pressure detection and easy maintenance, while maintaining compatibility with various game controller structures.
Implementation Method 1
The soft material sensor has an elasticity. When the user presses a portion of the key cap, a part of the soft material sensor corresponding to the portion of the key cap is pressed downward by the key cap
Implementation Method 2
The pressure sensor realizes a pressure sensing function by virtue of a pressure sensing element or charges of a flexible printed circuit board. When a force exerted by a finger on the pressure sensor is larger, a pressed area of the pressure sensor is larger, the flexible printed circuit board will sense pressure signals and convert the pressure signals into digital signals
Data Source
AI summary
A button assembly adapted for being mounted in a game controller. The button assembly 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 two active portions protruded outward. The two active portions are mounted to the two limiting portions, respectively. In processes of pressing and releasing the key cap, the two active portions move downward and upward with respect to the two limiting portions.